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Market Mix for Hard Materials

Aerospace. Heavy duty. 10%. 10%. PCBN Metal Cutting Tools Market by Industry. Other. 10%. Automotive (Major). 50%. Automotive (Suppliers). 20%. Market Mix for Hard Materials. Europe market size is over €130M. 2. 1996 Europe Market: €35M. N.America. N.America. N.America. Japan.

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Market Mix for Hard Materials

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  1. Aerospace Heavy duty 10% 10% PCBNMetal Cutting ToolsMarket by Industry Other 10% Automotive (Major) 50% Automotive (Suppliers) 20% Market Mix forHard Materials Europe market size is over €130M 2

  2. 1996 Europe Market:€35M N.America N.America N.America Japan Europe Japan Other Other Japan Other Europe Europe 25% 34% 36% 33% 21% 30% 9% 36% 36% 10% 20% 10% 1996 Market: $150 m 2001 Europe Market:€70M Super Alloy 5% Hard Ferrous Market by Workpiece Material Cast Iron 42% 53% PCBN Metal Cutting ToolsMarket by Region From ‘96 to ‘01 the market doubled in size 3

  3. Source: De-Beers Which PCBN Cutting Material ? • Low CBN - content • • IB 90 • • IB 80 • • IB 50 • • IB 45 • High CBN - content • Characteristics • Properties • CBN- content 80-95% • Fracture toughness • High thermal conductivity • CBN- lower 60% • Compressive strength • Low thermal conductivity • Preferred • applications • Roughing • Finishing • • Hardened steels • • Chilled cast iron • • Hard facings • • Pearlitic grey cast iron • • Hardened steels • • Hard facing • • (Cast irons) • Finishing • • Chilled cast iron • • Pearlitic grey cast iron

  4. Restriction ofhard turning and grinding • Hard turning • Diameter accuracy • because of limited chip thickness • in - process – measuring and correction at µm- range is impossible • Surface • 0,2-0,5µm • Interrupt cut • vibration • Crossing between hard and soft • high wear • Grinding • geometry flexibility • low • Set up time • high by complex Work pieces • Cutting time • high

  5. Comparison hard turning - grinding

  6. Hardened work piece Grinding or Turning ?

  7. Requirements for successful hard turning • stable machine • stable work piece clamping • accurate geometry of the soft part • Constant depth of cut • define the depth of hardening • take care of critical zone / • between hard and soft material

  8. small bur high precision At long work pieces grinding of different diameter at the same time No problem at the area of hard and soft material Low tool cost Dry cutting Low setup time Advantage Turning Advantage Grinding

  9. Typical Part's

  10. Project Hard Machining of „INPUTSHAFT“ and „OUTPUTSHAFT“

  11. Example 1 4.0

  12. Example 2

  13. Results • Continues constant Process • Tool life 500 part's • 20% time saving

  14. Example 3

  15. Existing Circumstances • Building up of a new transfer line • Replacement of grinding by hard machining • Work pieces are surface layer hardened( 0.8 - 1.1mm ) • 2 different grooving shapes • Grooves are pre-machined differently

  16. Hard turning

  17. Trial to turn the profile groove with ISO inserts Halter: SVNNR/L...F Wendeschneidplatte : VNMG 12T3... Not possible !!!

  18. Grooving before hardening to get a constant depth of cut for hard turning Strong bur Critical hard-soft Zone Solution Problem: Solution:

  19. Why „Pre-Cutting“?? Without Pre-Cutting the depth of hardening is not enough for machining. CBN-tipped inserts would machine not only the hardened but also the soft area! Result: Insert breakage.

  20. Applied Inserts • Pre-grooving „Busen“-groove • left: not pre-grooved after gear-cutting • right: pre-grooved after gear-cutting • Insert: CBN-tipped • Pre-Grooving of soft workpiecewith standard-insert

  21. Applied Inserts • Profiled grooving-insert forProfile-groove • CBN-tipped

  22. Applied Inserts • Profiled grooving-insert for„Schräg"- groove • right: not pre-grooved after gear-cutting • left: pre-grooved after gear-cutting

  23. Requirements • General allowance after hardening 0.15 mm • Depth of hardening 0.80 - 1.10 mm at ca.62HRc • Vc = 180 - 220 m/min • f = 0.30 - 0.60 mm

  24. Results • Machining time of 1-2.5 sec. per groove • Very high accuracy in shape and position achieved • Tool life up to 1.000 grooves per cutting edge with pre-machined grooves after gear-cutting • After reducing the feed to 0.06 mm very good surface. With higher feed slight chattering. • For highest rigidity the largest possible size of blank has to be used. • Close to the ground of the groove the feed should be reduced to 0.03 mm.

  25. Example 4 Work piece: Shaft 20MnCr5 mit 59-63 HRC Grooving: width of cut 2,11 mm Depth of cut 3,2mm (Pre-Cuttingallowance of 0,25 mm)

  26. Special Tool

  27. Result Tool life Competitor 500-550 ISCAR 1050

  28. Example 5 Work piece Shaft Work piece material 1.7321 HRC 60 Machine Gildemeister Power 15 kW Tool GHDL-25-0401320 Insert GITM-4-1401319 IB50

  29. Requirements • Increase tool life • Constant and stabile process • on a distance of 2 mm max deviation of 2 µ • Surface Rt = 1,6

  30. Special tool

  31. Competitor Insert = 2,36 CBN 22 Vc = 130 m/min f = 0,03 mm Tool life = 135

  32. Competitor • Schneideinsatz • CBN 22 • Vc m/min • 130 • Standmenge/ Einstiche • 135 Result • Iscar • GITM-4-1401319 IB50 100 % more tool life • 130 • 270

  33. Highlights 2002 CBN GROOVING BUILDED CHAMSHAFTS • Situation before the tests: • Customer use standard • GITM-6,00K-0,40 IB-50 • tool life of 200-250 pcs. • 2. If we can not reduce the cost • min. 40-50% the customer • wont to grind the work pieces

  34. Highlights 2002 Details: Work piece: Camshaft (500 pcs. each day) Material: 100 Cr6 ( 55 - 60 HRC ) Machine: Boehringer M160 Mounting System: Capto C4 Tool: C4-GHAD / GAD-5N Insert: GITM 6.00K-0.40 vc: 116 - 160 m/min (1850 U/min constant ) Feed: 0,12mm/U ap: ca.1,4mm

  35. Highlights 2002

  36. Highlights 2002 IB 55 Solution: New CBN IB-55 Result: tool life 350 – 450 pcs/cutting edge same cutting conditions!

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