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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Selecting the right grade
00:00

Selecting the right grade for the specific application is crucial for the success of a PCBN-test. The selection should be based on the application, but it is also important to look at the existing grade, cutting data and tool wear to be able to make the right choice.

In a continuous application, turning the face and inner diameter of a gear, a typical H05 application, a hard and wear resistant grade like CH0550 should be the right choice, but testing was not successful.



The competition was using a tougher grade suitable for more interrupted turning. Tool wear was chipping of the insert. Looking at the surface of the component, it was obvious that there were small vibrations present.

In this case it was not possible to reduce the vibrations (by changing machine tool, clamping etc), so CBN060K was selected, which is tougher than CH0550, and more able to resist the vibrations, and the result was 25% longer tool life than the competitor.


Two conclusions can be drawn from this:
  1. When selecting the grade, look at the application, and look at what the competitor is using. In this case, the competitor had selected the right grade. 
  2. CBN060K has been available for a while, but it is part of the HPT-chain, and still a very good grade, and it has its given position in the wear resistance versus toughness (ISO application area) chart, fully capable of beating any competitor in the H15 area. In a continuous application, turning the face and inner diameter of a gear, a typical H05 application, a hard and wear resistant grade like CH0550 should be the right choice, but testing was not successful.
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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CH0550 continues to beat the competition
00:02

The new HPT-grades continue to show good results. When machining of a cylindrical part on a clutch cover, CH0550 improved tool life by 30% compared to the competitor.
The surface criterion was Rz < 2 mm, and a wiper insert was selected, CNGA120408S-01525-L1-WZ-B, CH0550. An additional test was done with a larger nose radius, and that improved tool life with another 10%.


The competitor could also select a larger nose radius and maybe get more tool life, but he had not done that. Instead we strengthened our relationship with the customer by being the practical experts and offering him the best solution.

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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Secomax™ New PCBN grade chain
01:37


High performance PCBN Grades for hard part finish turning


Don’t miss the opportunity to utilize the great performance of the new PCBN grade chain for hard part finish turning. These grades show top class performance in four different ISO application areas and at the same time they have a well-balanced overlap so that a lot of different machining strategies can be selected, all depending on the customer demand.

Use the wear resistance of the new H05 grade or select some of the tougher alternatives perhaps in combination with a wiper, SECO now have a lot of PCBN options available for any hard turning application. CH0550, CBN060K and CH2540 are available as solid and brazed, solid inserts are normally the most cost effective solution.

Make sure that You find the optimal solution for Your hard turning application.

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

Product Manager:
Anders Wickman
Product Manager SECOMAX PCBN/PCD/CERAMIC
SECO TOOLS AB
737 82 Fagersta, Sweden
Office +4622340254
Mobile +46703431200
e-mail:anders.wickman@secotools.com



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Secomax™ CH3515
07:52

High performance PCBN Grades for hard part turning 

CH3515 was launched in SECO NEWS 2016-1 and is a completely new grade for H35, heavy interrupted cuts.


If there is a turning operation with really heavy interruptions, for example OD turning of splines the new CH3515 is the correct choice.

 Especially if the interruption is not chamfered the application must be seen as H35.

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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