Ceratizit Presents Team Cutting Tools and Turns Turning Upside Down

Komet has developed a drilling tool which leaves behind a chip-free component when producing through-holes in voids and chambers.

The tool designed for reboring has special chip control inserts mounted in the flutes which cannot be manufactured conventionally. The special design of the chip control groove and the coolant hole with backwashing can only be produced using additive technology by laser melting in 3D printing.

Compared to conventionally produced PCD face milling tools, which are equipped with either soldered PCD cutting edges or adjustable cassettes, the new, additively produced Komet PCD cutters showcase almost twice the productivity. This is due to the fact that the new process enables significantly more cutting edges to be achieved than was previously possible on a tool with the same diameter. 

High Dynamic Turning promises 40% higher feed rates, no tool changes and 90% less empty travel during turning. 

The defining characteristic of FreeTurn tooling is its simple structure. The tool holder, together with its slim shank and axial concept which optimizes the direction of the cutting forces into the spindle, form a stable unit. At the front there is a multi-sided insert, which is simply screwed in place. The trick: The patent pending FreeTurn insert can consist of several cutting edges with different properties. This allows for different angle points, corner radii or chip breakers - even different coatings and cutting materials are conceivable. 

Laser processing of PCD tools: cutting edges machined with the laser achieve tool life increases of 20 to 30 percent, as, unlike ground tools, they are significantly less jagged and have a sharper cutting edge. This is independent of the PCD grade used.  

Automation of monotonous work operations: With the introduction of the brushing robot, it is possible to automate cutting edge preparation with consistent quality and repeatability. 

Carbide tools are mainly manufactured by grinding. The cutting wedge produced has a very sharp cutting edge, which is not stable. This is why microchips form after a short machining time, thus leading to undefined change in the shape of the cutting edge. A short tool life is the consequence of this. A solution for this is a cutting edge preparation with a geometrically defined shape, which in most cases is applied using a diamond brush. Until recently, this was a manual operation, the quality of which was highly dependent on the skill of the worker.

At Ceratizit Balzheim's R&D center, trochoidal milling is performed on a 5-axis Hermle C 42 machining center to achieve higher machining parameters than conventional milling when cutting a TiAl6V4 workpiece for an aerospace application. 

Ceratizit's assistance system ToolScope allows for an objective and transparent analysis of the production process. Using various applications, it can be employed for monitoring, regulating, optimising, and documentation. It captures process forces (torque) primarily via the current consumption. This data is then prepared using algorithms and statistical process control. 

In February 2018, the “electronic route card” was introduced in the Stuttgart plant, so as to further increase the efficiency of production processes. The system used is a so called e-paper system, which is also found in e-book readers and in retail. Drawing from these areas, the technology was adapted for use in industry production.

Maria del Rey, quality technician for Ajalvir, Spain-based EDR System SA, explains how the company is cooperating with Ceratizit on the High Dynamic Turning technology to optimize the production of racing bike's Rotor hubs.

For over 95 years, Ceratizit has been developing and producing sophisticated hard material cutting and wear protection solutions: From highly specialized cutting tools, indexable inserts and carbide rods to new types of carbide and cermet grades for wood and stone working. The photo shows the Reutte facility in Austria.