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News and press releases
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08/09/2009
Carbide specialist CERATIZIT offers a new solution for the machining of problem materials
Process security for the peeling of bars made of nickel-based alloys – not at all ‘exotic’ for CERATIZIT tools |
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Difficult to machine materials such as nickel-based alloys are gaining more and more in importance. At EMO 2009 in Milan, CERATIZIT'S expertise as both market and competence leader in the field of bar peeling of nickel-based alloys with guaranteed process security will be presenting a new solution, which can also be applied for large diameters.
Apart from the aerospace and automotive sector, the demand for such materials is increasing mainly when large components are involved in the power supply sector. These large components, such as high and medium pressure turbines as well as high-pressure compressors, require high-performance solutions, appropriate for heavy machining.
CERATIZIT allows for this development by combining innovative cutting materials with geometries specifically designed for the heavy machining of high-performance materials. In this context the recently developed products provided with CERATIZIT HyperCoat coatings ensured a breakthrough. The CERATIZIT researchers developed two grades which cover this particular application area on a large scale while additionally offering maximum reliability for the operators. The first product of this range is CTP5620, a fine grain grade characterized by high abrasion resistance in both the substrate and the layers. The second is a heat resistant tough grade, CTP5630, which shows advantages especially in less stable applications as it is extremely reliable even under unfavourable conditions.
At least of equal importance as the development of specific combinations of cutting materials and coatings is the optimum cutting edge geometry. The CERATIZIT specialists optimized the cutting edges, tailoring them exactly to the requirements of these new materials which, thanks to the special chip groove or cutting edge, results in excellent surface finish and optimum chip formation. The supporting chamfers necessary for this kind of application have been adapted in such a way as to guarantee reduced vibration and process security.
These developments were applied on the worldwide common insert type YNUF 201220, which is used as a single insert for smaller diameters and also as a finishing insert for tandem systems when it comes to large bar diameters. These new products enhance the CERATIZIT product portfolio for bar peeling operations of the most different materials.
Dr. Uwe Schleinkofer, head of the cutting tool development department at CERATIZIT: “The machining of nickel-based alloys requires extremely low cutting speeds (15 – 50 m/min) together with rather moderate feed rates of around 4-10 mm per revolution. Higher cutting speeds would lead to extreme vibration and insert breakage, i.e. damage of the work piece.”
Sascha Rode, bar peeling product manager at CERATIZIT: “This new solution is very promising. In addition to the smaller diameters of 20 to 60 mm the new solution is also suitable for the machining of bars with diameters larger than 200 mm. The characteristically improved performance achieved in bar peeling operations compared to classic turning operations is now also attainable for producers of ‘large’ bars.”
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“The characteristically improved performance achieved in bar peeling operations compared to classic turning operations is now also attainable for producers of ‘large’ bars.” Sascha Rode, bar peeling product manager at CERATIZIT.
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