CH2540 will replace CBN160C
22:50


28 standard items of CBN160C will be outgoing during 2016.

These items will be replaced by CH2540.

Outgoing date;
  •  1 pcs 2016-06-30 (low sales – will not be replaced)
  • 13 pcs 2016-10-31
  • 14 pcs 2016-12-31


Internally communicated in SECO-Change of no 11-0012.

If You have issues replacing existing CBN160C business with the successor CH2540 or some other standard grade, pls contact Your local SECO representative, or our Advanced Mtrl team.



Author:
Eva Söderberg
Administration SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS AB
737 82 Fagersta, Sweden
Office +4622340491
                        Mobile +46702784500
                        email:eva.soderberg@secotools.com
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Secomax™ CH2540
04:51

CH2540 the CBN160C successor with improved tool life


Seco has for a number of years been using CBN160C, which has been a well proven PcBN grade for interrupted cuts. (H25 application area).

CH2540 is based on a new grade platform using bimodal grain distributions, it contains 65 % cBN of submicron size with 15 µm grains added to the structure. This adds both wear resistance and toughness.

For even tougher application areas (H35 application area) CH3515 has been introduced.

Due to higher terminal conductivity compared with CBN160C, CH2540 requires higher cutting speed to achieve correct temperature in the cutting zone.

















If it´s not possible to increase the cutting speed an alternative can be to choose the grade CBN150 that with its structure and low CBN content can handle lower cutting speed and interruptions.


For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.



Author:
Per Ola Jönander
Product Specialist SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS AB
737 82 Fagersta, Sweden
Office +4622340818
Mobile +46703163555 email:perola.jonander@secotools.com
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Secomax™ CH2540 - Wiper inserts not just for increased surface finish
06:12

The new CH2540 has bimodal grain size distribution, where fine grained cBN (1 µm) with 15 µm grains added to the structure. One advantage of this type of structure is the crack deflection that the coarser grains cause.

Implementation of wiper geometries allows for feed rates of 300 percent of what could be attained with standard inserts, while achieving the same level of surface finish.

The tough CH2540 grade has once again proven successful during these cutting conditions.

At this customer has feed rate been increased from 0.14 mm/rev to 0.40 mm/rev and tool life from 500 parts to 800 parts.

This is not just a reduction of Time in cut with 65% it is also an increased tool life with 65%.

This is a true winning solution that will give the customer a real and quick cost saving.



















For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.



Author:
Per Ola Jönander
Product Specialist SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS AB
737 82 Fagersta, Sweden
Office +4622340818
Mobile +46703163555 email:perola.jonander@secotools.com
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Chip breaker on PCBN reduces down-time
05:25

In finishing turning of hardened steel components, where the hardness is 60-62 HRC with CBN, a chip breaker is not needed, but when the hardness is lower, problems with long chips can occur. This was the case at one customer machining components with a hardness of 50 HRC.

The solution was to use inserts with chip breaker, and chip breaking was improved, and as an added bonus tool life was also longer than with the competitor insert.

Seco Tools has been very active in the area of machining case hardened steel for many years.

After heat treatment, gearbox components like gears and shafts usually have a hardness of 60-62 HRC. During the subsequent hard turning, chip control is not a problem, the chips are brittle and will break also without a chip breaker.

When machining components with a lower hardness, there can be problems with long and stringy chips, which can scratch the surface, interfere with the tool holder and clamping or otherwise negatively impact the machining operation, increasing the need for machine stops to clean the machine.

In this case, the hardness of a shaft was only 50 HRC, and the customer had problems with chips scratching the surface. The Seco solution was to use a chip breaker insert.


With the chip breaker insert, there was no need to stop the machine and remove chips anymore, resulting in a much more trouble-free production, and reducing the machine down-time.

For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.

Author:
Henrik Sandqvist
Product Specialist SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS Shanghai CO., Ltd. Building 4, No 797,
Puxing Road, Pujiang Town, Minhang District,
Shanghai 201114, China
Office: +86 21 5426 5849
Mobile: +86 185 1520 6942
e-mail: henrik.sandqvist@secotools.com


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CH3515 – Tough productivity boost
06:14

We were contacted by one international customer about improving productivity in a machine cell which was a bottle neck in their production. After analysis of the said cell, one of the improvement possibilities was this facing operation with heavy interruptions. It was identified as an H35 operation and the new CH3515 was the obvious choice. The goal was to achieve 100 parts tool life to have the same change cycle as other tools. It was easily achieved and the success was total. Cycle time was reduced with 40 s per part, which results in 11 000 hours of saved machining time. Annually!


Workpiece
Component: Gear
Material: 20MnCr5, SMG-H3
Hardness: 60-62 HRc
Surface: Pre-machined

Conditions
Operation:
Facing of gear teeth, heavy interruptions

Insert
CNGA120412S-02020-L1-B

Cutting speed: 180 m/min
Feed rate: 0.06 mm/rev
Depth of cut: 0.10 mm
Cutting length: 12 mm/part
Time in cut: 20s

Result 
Tool life
CH3515, 100 parts/edge,

40s saved per produced part compared to grinding.



For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.




Author:
Stefan G Larsson
Product Specialist SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS AB
737 82 Fagersta, Sweden
Office +4622340572
Mobile +46761367807
email:stefan.g.larsson@secotools.com

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Face milling of case hardened steel with PCBN
02:55

Turning is the most common operation on case hardened steel components after heat treatment. The material “moves” during the case hardening process, and that is the reason why a finishing process is needed, to generate the required surface and dimensional tolerances. Typical components include gears and shafts etc for the automotive industry.

Still, there are applications also for finish milling of case hardened components. It could be a sealing surface where there are requirements on surface finish, but also on flatness.

Seco has been working with PCBN milling for many years, and have today both the experience and products to reach the customers’ goals. A typical example is a pump body, which has a sealing surface with requirements on both flatness and surface finish:




Currently grinding is used to finish the component, and the machining time per component is 8 minutes. The question is, can this be done with CBN?

The component was clamped in a 3-jaw chuck in the larger end, and supported by a tailstock at the smaller end in a machining center.

An adjustable square shoulder milling cutter, 63 mm in diameter, with four positive full-faced TPGW11 CBN-inserts (3 cutting edges per insert) was selected:
  • Cutter R220.68-0063-TP11C-4, z=4 
  • Insert TPGW1103PNS-LF, CBN200 
and the following conditions were used:
  • Cutting speed 250 m/min 
  • Feed rate 0.07 mm/tooth (350 mm/min) 
  • Depth of cut 0.1 mm 
After machining of the first component, measuring was done, and it was well within the required tolerances. It was decided to continue and evaluate tool life, and it was possible to machine 106 components, equal to about 70 minutes time-in-cut.

So, what was the machining time when using CBN? For each component, the machining time was reduced from 8 minutes to 36 seconds. This is a large improvement, especially when you are making 1 400 components per day!

For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.

Author:
Henrik Sandqvist
Product Specialist SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS Shanghai CO., Ltd. Building 4, No 797,
Puxing Road, Pujiang Town, Minhang District,
Shanghai 201114, China
Office: +86 21 6091 2832
Mobile: +86 185 1520 6942
e-mail: henrik.sandqvist@secotools.com



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Secomax™ CH2540
07:18

High performance PCBN Grades for hard part turning

CH2540 was launced in SECO NEWS 2016-1 and is a completely new grade for H25, interrupted cuts, but also for mixed operations with both interrupted and continuous cuts.

CH2540 is developed to replace CBN160C and to be a part of the new grade chain and has bimodal grain size distribution, where fine grained cBN (1 µm) with 15 µm grains added to the structure. This adds both wear resistance and toughness to the substrate which leads to a larger working window.

There are more advantages

The new CH2540 is available in solid format. This format increase number of cutting edges. Comparing with CBN160C has number of cutting edges been increased with 100%.


While it is clear to see the economic and insert integrity advantages of solid PCBN, other advantages include reduced inventory and ease of handling of one multi-edged solid insert compared with several single or multi-tipped inserts required to achieve the same amount of work.

For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.



Author:
Per Ola Jönander
Product Specialist SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS AB
737 82 Fagersta, Sweden
Office +4622340818
Mobile +46703163555 email:perola.jonander@secotools.com
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