processes Cutting-edge
processes Cutting-edge solutions for titanium and stainless steel High-performance precision tools for turning and milling are essential for the economical machining of difficult-to-cut high-performance materials such as titanium and stainless steels. Boehlerit has been a competent partner for customized cutting inserts for many years – especially for machining materials that are difficult-to-cut. The HiPIMS coating technology from CemeCon is an important component for cutting inserts that adapt perfectly to these demanding applications. The ability to develop its own coatings and adapt them specifically to different applications gives Boehlerit the decisive edge – especially for demanding machining tasks. Hard metals and precision tools from Boehlerit solve demanding machining tasks worldwide and set standards in the machining of metal, wood, plastic and composite materials. The Austrian experts’ recipe for success undoubtedly includes a high level of vertical integration with state-of-theart technologies and extensive know-how in all facets of tool manufacturing – from design to coating technology. With the CC800® HiPIMS coating system as one of the key components, Boehlerit is setting new standards in the processing of high-performance materials. HiPIMS technology brings competitive advantages HiPIMS technology significantly increases the quality and performance of the coatings even further: HiPIMS coatings are very smooth, hard and tough at the same time. They have excellent adhesion and ensure optimum wear protection for the tool thanks to the uniform coating thickness distribution. Boehlerit benefits from both the exceptional performance of HiPIMS coatings and the flexibility of the coating systems. The ability to customize coatings to the requirements of specific applications makes all the difference – especially for demanding applications. For example, the technology makes it possible to produce coatings with adapted residual stresses – a decisive advantage for processing difficult materials. Processing titanium at the highest level Boehlerit has developed new cutting inserts to machine unalloyed titanium grades such as Ti (ASTM1-11), α alloys or α+β alloys (e.g. Ti-6Al-4V) with a high degree of reliability. In practice, these achieve up to 40 % longer tool lives than conventional solutions. “We owe these great results to the coordinated combination of selected carbide, special chip former geometry and high-performance HiPIMS coating” says André Feil, segment manager machining at Boehlerit. “The carbide base is a K10 ultra-fine grain substrate. It is particularly temperature-stable and has a low tendency to The combination of selected carbide, special chip former geometry and high-performance HiPIMS coating ensures the best results when turning titanium The HiPIMS coating with multilayer structure completes Boehlerit’s new solution for milling stainless steels plastic deformation. The specially developed MT (medium titanium) chip former with its sharp cutting edges ensures reliable chip breaking during medium and light roughing. And the icing on the cake is the 3 µm thick HiPIMS coating based on AluCon® (TiB2).” The low affinity to non-ferrous metals and the high hardness make the TiB2 coating so successful when machining titanium with sharp cutting edges. The HiPIMS coating material provides optimum protection against built-up edges. The extremely smooth coating surface ensures efficient chip removal. Thanks to the reduced friction, the temperature in the cutting process is reduced. The result: significantly longer tool life. The very good adhesion, coupled with the high hardness of up to 5,000 HV0.05, enables top performance in wet and dry machining – often with increased cutting data. 36 no. 3, September 2025
processes Unsurpassed for stainless steels High abrasive wear, poor chip breaking, built-up edges – milling stainless steels is one of the most demanding tasks in machining technology. “Such high demands require a perfectly sophisticated tool concept. Our newly developed BCM35M and BCM40M grades for milling stainless steels provide users with the perfect solution to these challenges” says André Feil. Proprietary HiPIMS coating for maximum performance Both milling grades are made of ultra-fine grain carbides with an optimized hardness-to-toughness ratio – i.e., abrasion resistance paired with fracture toughness. Boehlerit determined the chip formers and edge preparation after extensive simulations and application tests. The result: optimum cutting ability and perfect chip flow. André Feil: “We are breaking new ground with the coating and have developed a multilayer HiPIMS coating: it consists of alternating AlTiN and AlCrN individual layers. The multilayer structure results in excellent abrasion resistance, even at higher temperatures, combined with good fracture toughness. It also The CC800® HiPIMS coating system in use at Boehlerit delays the formation of cracks. Extremely smooth layer surfaces minimize built-up edges and ensure excellent machining results when milling stainless steels.” further information: www.cemecon.de design / manufacture / measure Gleason presents Smart Loop Gear Manufacturing at EMO 2025 in Hanover, Germany. This year Gleason will present groundbreaking innovations across the full spectrum of gear technology – from digital design and high-precision manufacturing to nano-level inspection – with a particular focus on Smart Loop Gear Manufacturing. At the heart of Gleason’s presentation is the seamless transition from gear design to manufacturing. The latest KISSsoft® Gear Design Software, now integrated with the KISSsoft System Module, offers advanced capabilities for simulating complete transmissions and gearbox components. These innovations streamline the engineering process and will be showcased live at the booth. In manufacturing Gleason introduces several new solutions tailored to small and medium-sized gear production. The Phoenix® 100C bevel gear cutting machine enables fast, userfriendly production of high-precision bevel gears for robotic and industrial applications. For differential gear systems, the Coniflex® Pro manufacturing system sets new standards in a closed-loop environment, significantly reducing surface stress and root bending while improving NVH performance and transmission accuracy. For hobbing and chamfer cutting, the Genesis® 280HCD offers exceptional flexibility by combining chamfer hobbing and fly cutter chamfering in parallel with gear cutting operations – ideal for both large-scale production and adaptable small-batch manufacturing. Additionally, the compact 100PSiC power skiving machine brings together power skiving or hobbing with sequential radial chamfering in a single machine, efficiently processing gears and shafts, even with complex contours. In gear inspection, Gleason unveils the 175GMS nano gear metrology system, which delivers submicron precision using a skidless probe and advanced evaluation tools such as wavi - ness analysis and the KTEPS kinematic transmission error prediction software, enabling fast and accurate diagnosis of gear noise and surface deviations. Visitors can experience the speed of the QFS quick-flex system, where workholding changeovers take less than 30 s, and see the latest hydraulic and mechanical clamping systems designed for precision and ease of handling across a wide range of machining needs. Complementing the machinery, Gleason presents a broad range of tooling solutions. These include high-performance hard finishing tools for grinding and honing, carbide power skiving cutters for any machine platform, and a full portfolio of European-made HSS and carbide hobs and milling cutters, including worm gear hobs and coarse pitch hobs, suitable for automotive, industrial and many other applications. Gleason will demonstrate how digital maintenance tools, modernization programs and expert support ensure maximum uptime and performance across the entire machine lifecycle. EMO 2025, hall 13, booth D18 further information: www.gleason.com no. 3, September 2025 37
