MACHINING SOLUTIONS FOR INDUSTRIAL SECTORS - CeramTec
SPK Cutting Tools VEHICLES AEROSPACE GEARS & BEARINGS MACHINING SOLUTIONS FOR INDUSTRIAL SECTORS ENGINEERING WIND ENERGY
TABLE OF CONTENTS 4-5 Machining Solutions for Industrial Sectors 6-8 SPK Engineering 9 - 11 TREND SETTING High-performance Cutting Materials 12 - 13 Tools for AEROSPACE 14 - 15 Tools for Turning 16 - 17 Tools for Hard Turning 18 - 19 Tools for Grooving 20 - 21 Tools for Milling 22 - 23 Tools for Boring
AUTOMOTIVE INDUSTRY 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 and increased productivity is always top priority. Component examples: Brake discs, gear components, fly wheels, clutch plates, brake components, drive shafts, hydraulic elements, engine/motor components MACHINERY AND PLANT ENGINEERING Manufacturing complex components made of different materials with extreme precision and optimal surface quality in an economic way – that is the basic structure of requirements for which we work together with our customers to create innovative, cost-efficient machining solutions. Component examples: Gearbox housing, flanges, guides, shafts, rollers WIND ENERGY In the field of wind energy, components mostly require special machining solutions, since the components involved are often especially large. Strict tolerance requirements and a high level of surface quality place extreme demands on the cutting materials and tool holders. By observing and analysing the determining factors for machining, we are able to provide our customers with extremely efficient and cost-effective machining solutions. Component examples: Rotor flange, rotor blade connections, planetary gear holders, gearbox housing, gear components GEAR TECHNOLOGY, DRIVE TECHNOLOGY AND BEARING INDUSTRY Surface quality, tolerances and the tool life of the cutting materials are the standards for quality for hard machining. Our unique range of cutting materials made of PcBN and ceramic, together with our perfectly matched tools, set the bar in this industry. In practice, this results in highly efficient and cost-effective machining. Component examples: Gear wheels, shafts, large gearbox components, bearing rings and rolling elements 4 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 economic and efficient. Our tools and cutting materials make these kinds of solutions possible. Component examples: Wheel rims, shafts, bearings AGRICULTURAL AND CONSTRUCTION MACHINERY We offer highly efficient bearing solutions for components for agricultural and construction machinery. Our range of solutions are currently used for machining of soft steel as well as processing cast iron and hardened parts. Component examples: Brake components, drive shafts, hydraulic elements, motor components AUTOMOTIVE For over 50 years, precision tools from CeramTec have been an integral part of highly productive machining solutions for components from the automotive industry: Component examples: Brake discs, brake drums, fly wheels, connecting rods, gear components, engine blocks 5 Motor industry Transport Agricultural and construction machinery Automotive
“We optimise machining productivity in your production processes” “We tap into the potential of your machining processes” Engineeringleistungen Redesigning and optimising machining processes Machining plans for optimal machining results Machining support Consulting Designing cutting data Defining tools “We bridge the productivity gap in your machining processes” Productivity gap Productivity Input engineering As opposed to a comprehensive view of the machining process, the focus for machining tools is solely on the purchase price. In practice, it has been proven that machining costs can be reduced by up to 4% based on the purchase price of machining tools. Optimised machining processes, however, result in significantly greater and, more importantly, sustainable savings potential. Real-world examples have shown that a range of 15 to 30% lower machining costs are possible. We have grouped our engineering services under the name SPK The Productivity Experts. Based on our customers’ needs, we approach the optimisation of machining processes in three steps: machining technology machine. Reducing the overall production costs per part by increasing the machining volume by 20% 50% price reduction per insert ca. 4% SPK tools provide the manufacturing industry with a wide range of state-of-the-art cutting materials, coatings, insert geometries and tool holder systems to create the optimal solutions for machining tasks. These tools make it possible to manufacture products that are characterised by extremely high precision in limited tolerance ranges and perfectly matched surface qualities. Efficient implementation of these attributes is primarily influenced by two factors: the performance of the machining tools and the amount of practical knowledge regarding the use of our precision tools, whereby practical knowledge is becoming increasingly important. It brings to- gether cutting materials and tools with the materials, components and the machine situation to create processes with increased productivity and reliability. 6 SPK tools from CeramTec GmbH draw on the knowledge and experience that has been acquired through 50 years of high-performance machining and uses this know-how to create the optimal solution for nearly any application. Our SPK engineering team’s scope of activities ranges from the comprehensive optimisation of machin- 7 ca. 16% ing processes all the way to traditional application-based support and consulting and much, much more. With their machining expertise, our high-performance cutting materials and modern tool systems, our experts are able to provide fieldproven, reliable solutions with the highest possible productivity in the shortest amount of time. 8 Our engineering team is there for you around the globe!
In terms of scope and variety, CeramTec offers an internationally respected, one-of-akind range of ceramic cutting materials, PCBN, cermets and a large number of coatings for machining tasks such as hard turning, turning, grooving, milling and boring. Cutting materials for hard turning Mixed ceramics CeramTec has one of the largest selections of PCBN and ceramic cutting materials for turning and grooving components made of hardened steel. Our solid PCBN variants are particularly optimal for implementing machining strategies that reduce process times. These composite cutting materials feature exceptional wear resistance, edge stability and red hardness. They are used for processing hardened steels, hard machining of rolls, and finishing and medium machining of cast iron parts. i SPK HIGH-PERFORMANCE CUTTING MATERIALS α/β SiAION ceramics i www.spk-tools.com/sialonceramics This cutting material is ideal for rough finishing, finishing and fine finishing of steel, sintered metal and cast iron with both continuous and lightly interrupted cuts. We offer a wide range of chip breaker geometries for optimum, reliable chip formation and chip breaking. www.spk-tools.com/oxideceramics i PCBN for machining cast iron www.spk-tools.com/siliconnitrideceramics i 9 www.spk-tools.com/cermets CSA cutting materials The unique and comprehensive range of PCBN high-performance cutting materials allows for the reliable HPC machining of grey cast iron and chilled cast iron. From continuous to interrupted cuts, these materials feature exceptional behavioural reliability and set new standards for machining speeds, tool life and reliability. Silicon nitride ceramic inserts are ideal for machining cast iron parts with high cutting data and high machining speeds. They ensure reliable production in a wide range of applications. www.spk-tools.com/hd-line Cermets These traditional cutting materials for turning and grooving are ideal for use in machining processes with grey cast iron and ductile cast iron as well as parts made using centrifugal casting. Silicon nitride ceramics i i Oxide ceramics These gradient cutting materials are characterised by extreme hardness and wear-resistant surfaces, as well as an exceptionally tough, stable core. Their wide range of possible applications when machining cast iron materials make them HPC specialists. i www.spk-tools.com/mixedceramics This cutting material is ideal for turning and grooving of engine components. It has opened up new horizons for machining engine components in the aviation industry. i www.spk-tools.com/pcbn-castiron 10 11 www.spk-tools.com/CSA
TREND SETTING CeramTec AEROSPACE We offer a complete package for engine construction in the aviation industry, consisting of our CSA cutting materials and the corresponding tool system, our Monsoon Tool Technology tool. 12 13 CSA115 The CSA cutting materials were developed for high-performance machining of engine components in the aviation industry. CSA cutting materials combine extreme wear resistance and exceptionally high reliability. This makes it possible to significantly reduce machining times for turning. MONSOONTOOL T E C H N O L O G Y The corresponding tool system, our Monsoon Tool Technology tool, uses integrated high-pressure cooling to ensure reliable chip breaking. The tool prevents the formation of problematic continuous chips and the CSA cutting materials can be used with high cutting data for the highest possible level of reliability.
TOOLS FOR TURNING SYSTEM S3 Tool holder With our turning tools for external and internal machining, our cartridges and our tool changing systems, we offer a large number of turning solutions that increase productivity, optimise processes and reduce costs. Boring bars Cartridges Our boring bars are designed for optimal chip removal while retaining a high level of stability against vibrations. Standard and special lengths, different diameters and a wide range of holder designs allow for reliable high-performance internal machining with our cutting materials. Our cartridges are designed in accordance with ISO standards. They can be adjusted axially and radially, which allows them to be used in a wide range of applications for external and internal machining. Our comprehensive range of standard and special tool holders are designed specifically for reliable high-performance machining with ceramic cutting materials, PCBN and cermets. They can be used in a number of applications from heavy roughing to medium machining tasks all the way to finishing and fine finishing. The range offers a wide spectrum of tool holder designs and insert types. S3 system standard and special turning tools can be equipped with extra features that significantly increase the reliability and the tool life of the tool holder. This allows the tool system to be flexibly adjusted on-location based on factory conditions. For example, clamping elements are available in carbide versions and tool holders are available in special materials. Modular tool changing systems Easy Change technology Heat protector This technology allows you to change the cutting material back and forth between ceramics and PCBN easily and simply and, with the S3 system, it ensures that the clamping element remains in the right position – even in overhead or sideways positions. For the S3 system, the insert can be made of high-performance ceramics, which allows it to provide thermal insulation. Precise machining of a part places great demands on the tool system, especially when changing tools. In order to meet the requirements for change precision, handling and stability, our tools are available in all standard interface systems. 14 15 ODC force clamping technology The S3 clamping technology ensures that the clamping force is optimally distributed so that the insert is reliably clamped as a result. Part of the clamping force is applied directly to the insert powerfully, creating a form-fit seal. Two thirds of the clamping force retracts the insert into the insert seating.
LEADING TECHNOLOGY TOOLS FOR HARD TURNING We offer a variety of PCBN and ceramic cutting materials along with the matching tool holder systems for hard turning and finishing of gears, drive components and bearing components for individual, series or mass production. Our HD-Line cutting materials include a comprehensive selection of coated PCBN and ceramic high-perfor- mance grades for continuous cuts all the way to heavily interrupted cuts for hardened components with hardness up to 63 HRC. Our ceramic cutting materials for hard turning are an excellent technological and economical alternative for continuous cutting. Hard Turning of a Gear To supplement our multi-tipped and laminated inserts, we also offer solid versions made of PCBN, which allows you to implement alternative machining strategies. Our insert preparation expertise and the wide range of cutting materials available for hard turning allow us to implement even the most challenging hard turning applications in an economic and efficient way. 16 17 Inserts for Hard Turning Hard turning with SPK tools Excellent surface qualities Increased process reliability Shorter process chains High dimensional and shape accuracy High process flexibility Cutting materials for hard-soft transitions Continuous and interrupted cuts
TOOLS FOR GROOVING GROUND BREAKING RA-Grooving System We offer a comprehensive range of standard and profiling tools for grooving and profiling. In our Engineering department, we design specially shaped grooving inserts and special holders, and manufacture them in our own in-house production facilities. When grooving with lateral movement, our RAG grooving system shows off its strength. The patented grooving insert’s double prism clamping allows for high cutting values with extremely high reliability. Standard and special inserts for grooving 18 19
TOOLS FOR MILLING Face milling systems and their major areas of use SPK milling type Face milling systems: Our milling systems were designed especially for high feed rates and high machining speeds. Depending on the type of milling cutter used, rough milling, rough finishing and finishing operations ranging all the way to fine finishing can be performed optimally. The wide range of ceramic, PCBN and cermet cutting materials offer economic solutions for a wide number of materials and milling tasks. Based on the machining task and part situation, we offer perfectly matched milling systems with negative or positive insert geometries, with wedge or centre hole clamping for highly productive milling. PFK PFL BFL PMK PDK PEK Rough milling Rough finishing Finishing Fine finishing Helix / high feed The Soft-Cut system is a highly positive milling system available for face milling with the lowest possible axial forces. With negative inserts and a setting angle of 75 or 45 , the PFK face milling system also allows for soft face milling with low cutting forces. Square shoulder milling and groove milling Our PFK milling system features exceptional performance for square shoulder and groove milling. High feed rates per tooth and effective chip removal along with moderate cutting force come together with a variety of cutting materials to create a reliable and durable milling system with a wide range of possible applications. High feed and helical milling The BFL milling system allows for maximum feed rates per tooth at high cutting speeds. Together with our corresponding standard inserts and standard cutting materials it can show off its highfeed qualities. The geometric design of the milling body allows for helical plunge milling into a workpiece in order to ensure the bearing seats are the right size. Cutting materials for milling Cutting material / material SiAION ceramic Silicon nitride ceramic Mixed ceramic PCBN Cermet Special tools and engineering When special milling tasks require special solutions, our Engineering department can show you their plans for how you can implement these milling tasks with standard or special milling tools efficiently and economically. The milling tools are then promptly manufactured exclusively in our own production facilities. Milling system PDK with adjustable finishing insert MFS 20 21 Working together with OEMs We offer support for original equipment projects based on our expertise and plans directly on-location at machine manufacturers’ premises and in person with our customers. GJL GJS
TOOLS FOR BORING TRAIL BLAZING We offer exceptionally powerful and flexible tool solutions for boring tasks: depending on the application, we can equip our boring tools with fixed insert seating or cartridges. For maximum efficiency, we design our boring tools with the optimum number of insert seats. In terms of the tool holder, we offer a comprehensive standard holder range – short taper, HSK taper or direct gripping. 22 23
THE PRODUCTIVITY E X P E RT S Nowadays, optimal machining of a part is no longer solely dependent on paying attention to the cutting process. Continuously improving materials, continuously increasing qualitative requirements for components and growing environmental challenges mean that the entire machining process must be viewed holistically and optimised both in terms of technology and efficiency. Our more than 50 years of machining experience makes it possible for us to design machining processes today that are highly efficient and low-cost thanks to our engineering services, coupled with our innovative high-performance cutting materials and our tool systems. Our Engineering department plays a major role in this process. It answers questions of how a component can be machined optimally with our precision tools thanks to innovative and cost-optimised manufacturing strategies. They put together machining plans and perform time and cost studies in order to optimise machining processes. In order to help our customers solve their machining challenges, we have made this process a standard as part of our programme SPK - The Productivity Experts with the engineering formula Tools Technology Application more productivity at lower costs. A large number of specific applications have already shown that our engineering formula significantly increases productivity and lowers costs for our customers from a wide range of industries. That is why we will be affixing a quality seal to our products in the future – our productivity compass, which is a sign of increased productivity for our engineered tools. Wherever you find our productivity compass, it will show you that the maximum contribution to productivity is the focus of our engineered machining solutions. Whether on our inserts, tool holders or even on processing machines, whenever the machining process has been optimised by our engineering on-location. Our productivity compass is the productivity seal you can trust. www.tools-for-productivity.com ITY TIV DUC PRO TOOLS ENGINEERED TOOLS FOR PRODUCTIVITY TECHNOLOGY COST S T TOOLS T TECHNOLOGY A APPLICATION APPLICATION ADDED VALUE A ADDED VALUE 24
CeramTec GmbH SPK Cutting Tool Division Hauptstrasse 56 73061 Ebersbach/Fils Germany Phone: 49 7163 166 - 239 Fax: 49 7163 166 - 388 info@spk-tools.com www.spk-tools.com / www.ceramtec.com 1309 IM 2.000 St. 70.91.49.951.3 m o c . y t i v i t c u d o r-pr o f s l o o t . w w w
been proven that machining costs can be reduced by up to 4% based on the purchase price of machining tools. Optimised machining processes, however, result in significantly greater and, more importantly, sustain-able savings potential. Real-world examples have shown that a range of 15 to 30% lower machining costs are possible.
Bruksanvisning för bilstereo . Bruksanvisning for bilstereo . Instrukcja obsługi samochodowego odtwarzacza stereo . Operating Instructions for Car Stereo . 610-104 . SV . Bruksanvisning i original
There are different types of machining process used for sapphire material. The fig. 1 shows a graphical representation of sapphire machining processes i.e. laser machining process, grinding process, polishing process, lapping process, new developed machining process, compound machining process and electro discharge machining process. Fig.1.
Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
PCI Machining - Absolute Machine Tools 7944 Innovation Way Mason OHIO 44053 USA 1 (513) 701-5550 sales-usa@pci-machining.com PCI Machining Rue Copernic 42030 - Saint-Étienne FRANCE 33 4 77 42 60 88 sales@pci-machining.com services@pci-machining.com PCI Machining Vertriebsbüro Deutschland Lebacher Straße 4
Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
where the use of 5-axis simultaneous machining brings unequalled surface quality. Moreover, it is targeted at prototype machining, 5-axis trimming and special machining where full 5-axis machining is the requirement for quick and accurate manufacturing. Multi-Axis Surface Machining is also an add-on product to Prismatic Machining and Lathe .
10 tips och tricks för att lyckas med ert sap-projekt 20 SAPSANYTT 2/2015 De flesta projektledare känner säkert till Cobb’s paradox. Martin Cobb verkade som CIO för sekretariatet för Treasury Board of Canada 1995 då han ställde frågan
& Beverages ensure food availability in the future. secure access to primary resources as well as productive operations that This is evidenced by repeated Chinese-led acquisition in foreign markets, targeting agricultural companies or meat, pork and poultry producers, mainly. Such was the case of Smithfields Foods (with Chinese WH Group as its controlling shareholder), which acquired several .
