GEARS & BEARINGS WIND ENERGY E ITUD MULT RA S COVE IS TION D U F SOL O HARD TURNING Cutting materials, tool systems and technologies for hard turning in the gear, drive and bearing industry

DISCOVER A MULTITUDE OF SOLUTIONS AEROSPACE The aerospace industry places extremely high demands on machining. In this field, machining capacity and process safety are the decisive parameters, and our CSA cutting materials together with our Monsoon Tool Technology tools are the optimal solution. Component examples: Jet engine components such as blisks AUTOMOTIVE INDUSTRY For over 50 years, precision tools from CeramTec have been an integral part of highly productive machining solutions for components from the automotive industry. With our tool solutions, the implementation of concrete cost savings...

AUTOMOTIVE INDUSTRY MOTOR INDUSTRY The high-performance materials that are used in this industry require cutting materials that ensure an extremely high level of process reliability and a consistently high quality level. Our cutting materials and tools are the perfect solution. Component examples: Connecting rods, pulley wheels, cylinder heads, cylinder liners TRANSPORT When machining components for the transport industry, special solutions are often required in order for the machining process to remain economical and efficient. Our tools and cutting materials make these kinds of solutions possible....

E-Mail: [email protected]

E-Mail: [email protected]

SPK hard turning solutions Increasingly, components made from hardened steel such as those used in the gear, drive or bearing industries are being machined using hard turning with modern cutting materials and tools. Accordingly, the high standards being set in surface quality dimensional and shape accuracy must be achieved with process reliability. Components in mass or volume production must be manufactured with the highest possible efficiency. In this context, hard turning is the production process that facilitates a drastic reduction in processing times, which leads to a significant decrease...

SPK hard turning grades The brand new cutting material and insert system for hard turning has been especially developed for highperformance hard turning operations. All types of cutting material have an exceptionally high edge stability and minimal crater wear. For the entire application spectrum – from continuous to lightly and heavily interrupted cuts – the high-perfor- mance specialists are well prepared with the range of new grades, which means that users can use the cutting materials to design the optimal hard turning process for their respective hard turning application. Multi-tipped and...

Solid PcBN inserts for hard turning – simply better WITH SOLID PCBN FOR HARD TURNING FOR: - NEW MACHINING STRATEGIES - HIGHER CUTTING DATA - AND HIGHER PROCESS RELIABILITY the carbide body, are often accepted. These limiting factors can be observed in the cut allocation (cutting depth is limited by the length of the PcBN insert), the cutting speed as well as the operation time (desoldering the PcBN insert due to levels of heat that are too high). Solid, low PcBN contend inserts are not affected by these limitations and offer numerous application advantages. ADVANTAGE: NEW MACHINING STRATEGIES...

ADVANTAGE: PRETURNING MACHINING TECHNIQUE With preturning, a type of facing method, maximum removal rates and hard to soft transitions can sometimes be achieved in one work step. This work step can also often be performed by implementing an insert geometry. The preturning machining technique does not just considerably increase efficiency, but also reduces the machining costs because a smaller range of tools is required. ADVANTAGE: HIGHER CUTTING DATA AND LONGER OPERATION TIMES Average cutting data for hard turning with soldered PcBN inserts is characterised as follows: a moderate cutting speed...

INITIAL CUTTING CONDITIONS WEAR RESISTANCE INTERRUPTED CUTS E-Mail: [email protected]

Recommended applications CUTTING SPEED RANGES Cutting speed vc: FEED RATE RANGES Feed rate f: Solid Solid Tipped Solid Tipped Tipped 240 Solid Multi-tipped Inserts Inserts Eckenbestückte Schneidplatte E-Mail: [email protected] FEED RATE

Recommended applications Recommended values for turning hardened steels Hardness (HRC) Recommended value for chip thickness h (mm) Cutting speed vc (m/min) Recommended CUTTING DEPTHS ap: Conventional hard turning: ap = 0.1 - 0.5 mm Hard to soft transition: ap max = 4.0 mm DETERMINING THE FEED RATE VALUES When working with a small depth of cut for hard turning, the chips will have a “C” shape with a specific thickness h. In order to obtain the optimum chip formation, the feed rate should be determined according to the given formula, depending on the variable chip thickness h. f=h•M Example: recommended...

Types of solid and multi-tipped versions DESIGNATION SYSTEM FOR INSERTS Designation of multi-tipped inserts with ZZ geometry Number of cutting edges (4 corners multi-tipped) Length of PcBN insert > 2 mm CNGA 120408 T - LL 95Z025 Width of the ZZ chamfer Chamfer Approach angle Designation of Solid inserts with IKS-PROMini clamping system Solid version SNGX 090408 S - S - MDO IKS-PROMini clamping notch Designation of Solid inserts with System S3 for inscribed circle 12,70 mm Solid version SNGX 090408 S - S - SDO Chamfered and rounded System S3 IKS-PRO based clamping notch Types of HD-Line inserts...

IKS-PROMini and System S3 for hard turning Our goal is to provide the ideal tool for every hard turning application. In order to meet the extremely high demands on positional and shape tolerances as well as surface quality, we have developed clamping systems which, in combination with our cutting materials, can reliably meet these strict tolerance requirements. IKS-PROMINI FOR SMALL INSCRIBED CIRCLES (≥ 6.35 MM) The IKS-PROMini clamping system is based on the IKS-PRO. The proven notch geometry used in IKS-PRO has been further developed in order to meet the requirements of hard turning with solid...