version 2013-1
Custom Tooling Winning Solutions EPB
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enhancing your competitiveness Seco works closely with manufacturers to create and provide solutions that increase productivity and bolster profitability. With 5,000 team members in over 45 countries, we offer a globally networked resource dedicated to solving your challenges and supporting your operations. Through cooperative partnerships with manufacturers and entities around the world, we monitor trends, identify challenges and develop solutions that overcome the industry’s most demanding applications. When you work with Seco, you experience a true partnership based on trust, respect and communication. Our solutions exceed milling, holemaking, turning and tool holding products, as we work closely with your team to address and improve every aspect of production. For over 80 years, Seco has developed the tools, processes and services that leading manufacturers turn to for maximum performance. Whatever challenges you encounter, our team is always nearby to help you overcome them through extensive expertise and high quality products. Seco customers can also access the latest information regarding new products, machining data, manufacturing techniques and other developments by visiting our website at www.secotools.com. Seco-EPB technologies........... 4
Wind Power
Agriculture
Seco-EPB Custom Tooling...... 5
Case 1: Wind turbine casing fine boring ø 3200 mm............. 8
Case 5: Casing multistep rough boring........................... 11
Case 2: Stator frame fine boring ø 2717 mm........... .8
Case 6: Combined boring bars for tractor engine.................... 11
Case 3: Wind turbine casing fine boring ø 2700 mm........... ..9 Case 4: Transmission shaft fine boring............................... ..9
Oil & Gas
Automotive
Case 7: Valve fine boring........ 13
Case 13: Cam and crankshaft line boring .............................. 17
Case 8: Hydraulic jack boring.... 13 Case 9: Three way valve back boring ............................. 14 Case 10: Screw pump fine boring...................................... 14 Case 11: Milling main block..... 15 Case 12: Water pump housing fine boring 2............. 15
Case 17: Multistep fine boring in casing (2)....................................20 Case 18: Square shoulder milling....20
Case 14: Cylinder housing, cam and crankshaft fine boring..... 17
Case 19: Examples of fine boring bars with Steadyline™...............21
General Engineering & Others
Case 20: Deep internal boring with Steadyline™.......................21
Case 15: Long overhang rough boring ............................ 19 Case 16: Multistep fine boring in casing (1)................................... 19
Case 21: Examples of multi-cut fine boring bars.........................22 Case 22: Examples of milling holders with Steadyline™.........22
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seco-epb technologies steadylinetm vibration damping system A built-in vibration absorber dampens the vibration as soon as it is transmitted by the cutting tool to the body of the holder; it prevents it from spreading along the bar, thus limiting the deflection of the assembly. Much higher cutting conditions, with quieter operation and optimium stability can be achieved, increasing productivity and surface finish, as well as the tool and the spindle life-time. In parallel to our standard range, the Steadyline™ technology is integrated in many Custom Tooling applications.
antifriction rotary bushings Used to support and guide the cutting tool, the rotary bushings consist of a stationary outer case and an inner liner, set on antifriction lubricated precision bearings, that rotate with the cutting tool. Bearings can handle any radial or axial load and provide the rigidity required to produce precision cuts. Advantages: • Built-in precision to bore quality 6 • Friction free rotation • Consistent part quality • Improved process capability
jumbo bridge bars For very large diameter boring, our range of Jumbo bridge bars provide unequaled results. Jumbo bridge bars exist as standard from ø654 to 2155 mm but we have designed and implemented, with success, bridges over 3 metres wide, with or without guides. Jumbo bridge bars made of high tensile aluminium with steel interface, are designed to hold two Bridge bars in several positions. Fitted onto a face milling cutter holder ø60 mm, or fitted directly onto the machine spindle (DIN2079/50 front end), or using the centering spigot.
micrometric adjustment Seco-EPB preferably uses the standard micrometric adjustment screws in all Custom Tooling applications. The setting mechanism ensures an adjustment down to 2,5 µm on diameter through a vernier scale. The precision of the mechanism guarantees repeatable accuracy.
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Example of 3d drawing supplied with CT-Offers.
seco-epb custom tooling seco-epb custom tooling support Our pricing department can offer a quick response to pricing requests, through our worldwide sales network. Complicated offers are submitted with easy to read 3D-CAD drawings. Our application engineers, with their strong technical background, will support you from enquiry to installation and implementation directly at your facilities. Our target is to provide you with a winning solution in the shortest possible time.
custom tooling workshop Seco-EPB’s Custom Tooling workshop is a separate entity within the main manufacturing plant; completely independent from standard ‘catalogue’ product manufacturing. Thanks to a complete range of modern mill-turn machines, precise grinding centres, and 3D control devices, we ensure a high level of quality and precision.
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wind power
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case 1: WIND TURBINE casing fine boring Material:
GGG40
Machine:
FPT, M+ARX, SA50
Operation:
Insert:
Boring: ø 3200 0/-0,3, 250 mm deep Boring: ø 3280H7, 10 mm deep Back boring: ø 3220H7, 15 mm deep Jumbo bridge bar in high tensile aluminium, 300 kg, length 2810 mm. TCMT110208F1-HX
Cutting conditions: (Ø 3200x250)
Metric Inch
Tool:
Metric Inch Results
vc 220 m/min 722 sf/min vf 3.3 mm/min 0.129"/min
fz 0.15 mm/rev 0.006"/rev ap 0.5 mm 0.02"
n 22 rev/min 22 rev/min
• Machining time: 75 min • Rz: 16 • Diameter deviation: 0.02 mm on diameter after 17km tool engagement
Case 2: stator frame fine boring Material:
Steel SMG3
Machine:
PAMA Speedram 4000, SA60
Operation:
Boring ø 25270/-0,25, 30 mm deep Boring ø 27170/-0,25, 90 mm deep
Tool:
Jumbo bridge bar in high tensile aluminium, 450 kg, length 2436 mm. CCMT09T308-F1, TP1500
Insert: Cutting conditions:
Metric Inch Metric Inch
Results
vc 200 m/min 656 sf/min vf 3.6 mm/min 0.14"/min
fz 0.15 mm/rev 0.006"/rev ap 0.5 mm 0.02"
n 24 rev/min 24 rev/min
• Machining time: 25 min • Roundness: 0.02 mm
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case 3: WIND TURBINE casing fine boring Material:
GGG40
Machine:
Horimaster 5, Schiess, SA60, 3 metre RAM at ø 560
Operation:
Insert:
Boring: ø 2690H7, 300 mm deep Boring: ø 2700H7, 65 mm deep Jumbo bridge bar in high tensile aluminium, 350 kg, length 2540 mm. CCMT09T308-F1, TK2000
Cutting conditions: (Ø 2690x300)
Metric Inch
Tool:
Metric Inch
vc 169 m/min 554 sf/min vf 3.0 mm/min 1/2 finishing 0.118"/min
Insert:
CCMT09T308F1-TK2000
Cutting conditions: (Ø 2700x300)
Metric Inch Metric Inch
Results
fz 0.15 mm/rev 0.0006"/rev ap 1 - 1.25 mm 0.039 - 0.049"
n 20 rev/min 20 rev/min
fz 0.15 mm/rev 0.006"/rev ap 0.5 mm 0.02"
n 20 rev/min 20 rev/min
vc 169 m/min 554 sf/min vf 3.0 mm/min Fine boring 0.118"/min
• Machining time: 100 min • Rz: 10 • Diameter deviation: 0.03 mm on diameter after 17 km tool engagement
case 4: Transmission shaft fine boring Material:
Case hardened steel (58HRc)
Machine:
Millturn Mori Seiki- HSK-A100
Operation:
Boring internal profile ø 280H7, ø 319H7 Grooving and threading
Tool:
Insert:
Boring bar with integrated Steadyline vibration damper, L=800 (9xD), 43 kg. Roughing and fine boring with the same cutting head with 2 different inserts at 180°. CCMT09T304-F1, TH1500 & TH1000
Cutting conditions:
Metric Inch
Results
vc R: 80 m/min F: 150 m/min
ap R: 2 mm F: 0.3 mm
fz 0.15 mm/rev
R: 262 sf/min F: 492 sf/min
R: 0.079" F: 0.012"
0.006"/rev
• Improved surface finish • Higher productivity • Increased insert life time
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agriculture
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case 5: casing multistep rough boring Material:
Cast iron
Machine:
MCM
Operation:
Multistep rough boring, ø 75, ø 87,5, ø 109 Chamfering 30° in one step
Tool:
Boring bar (4 cartridges) with antifriction rotary bushing with radial compensation.
Insert:
CCMT09T308-F1, TK2000 CCMT120408-F2, TK2000 CCMT160508-F2, TK2000
Cutting conditions: Results
Metric Inch
fz ap vc 120 m/min 0.25 mm/rev 37 mm/diameter 394 sf/min 0.01"/rev 1.45"/diameter
• Machining time: 30 sec. Previously made by interpolation milling: 10 min
case 6: EXAMPLES OF BORING BARS COMBINED WITH STEADYLINE™ VIBRATION damping SYSTEM FOR TRACTOR ENGINE COMPONENTS
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oil & gas
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case 7: valve fine boring Operation:
Long overhang fine boring with interrupted cut
Tool:
Boring bar D=75xL=700 (9xD) with integrated damper.
Insert:
CCMT09T304-F1, CP500
Cutting conditions: Results
Metric Inch
vc 150 m/min 492 sf/min
fz 0.10 mm/rev 0.004"/rev
• Improvement in insert life time, productivity and surface finish
case 8: hydraulic jack boring Operation:
Boring ø 210-350, depth up to 8000 mm
Tool:
3 cartridge boring head with antifriction rotary bushing with radial compensation.
Results
• Improvement in productivity
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case 9: 3 way valve back boring Material:
Forged Duplex stainless steel SMG10
Operation:
Back boring ø 96, ø 142, ø 169 and ø 202
Tool:
Boring bar with integrated damper, interchangeable cutting heads, perfomed with Jetstream Tooling®.
Insert:
Roughing: CNMG120408-M5, TP3500 Finishing: DNMG150608-MF1, TS2000 ap vc Metric 40-80 m/min R: 2 mm F: 0.012 mm Inch 131-262 sf/min R: 0.079" F: 0.012" fz
Cutting conditions:
Metric Inch Results
0.25 mm/rev 0.01"/rev
• Improvement in productivity, insert life time, and surface finish
case 10: Screw pump housing fine boring Operation:
Fine boring with interrupted cut
Tool:
Carbide fine boring bar with integrated vibration damper, up to 12xD fitted in OZ collet chuck.
Insert:
CCMT09T304-F1, CP500
Cutting conditions: Results
Metric Inch
vc 150 m/min 492 sf/min
fz 0.10 mm/rev 0.004"/rev
• Improvement in productivity, insert life time, and surface finish • Consistency in centre distance of the bores • Consistency in size of main and idler bores
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case 11: milling main block Material:
Steel SMG4
Machine:
Juaristi, SA50
Operation:
Helical interpolation milling ø162x442
Tool:
E3471555532520, SA50 Steadyline™ d=32 x A=520 with high feed cutter R220.21-0088-160-5C, ø 88 x GPL550
Insert:
218.19-160T-04-M08, F40M
Cutting conditions: (Ø 3200x250)
Metric Inch Metric Inch
Results
vc 144 m/min 472 sf/min n 520 rpm 520 rpm
fz vf 0.96 mm/tooth 2500 mm/min 0.038"/rev 98"/min ap 1 mm 0.039"
• 42 minutes, 64% better than with previous solution • Better surface finish
case 12: water pump housing fine boring Operation:
Blind, multistep fine boring
Tool:
Boring bar with lubricated guiding bushes, alu bridges with 3 adjustable fine boring heads.
Results
• Improvement in productivity
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Automotive
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case 13: cam and CRANKSHAFT line boring Operation:
Fine boring ø 58H7 and ø 87H6 in one step
Tool:
Adjustable fine boring head (type Libraflex® or Liteline®) performed with antifriction rotary bushing.
Results
• Achieving concentricity within 20 microns
case 14: cylinder housing, cam and crankshaft fine boring Operation:
Semi-finishing and fine boring, line boring
Tool:
• Boring bar for semi-finishing and finishing cylinder housing in one step with 3 PCBN inserts (1 wiper for finishing). • Steadyline™ fine boring bars with micrometric adjustment for cam and crankshaft line boring.
Results
• Improvement in productivity
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general engineering & others
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case 15: long overhang rough boring Material:
Steel SMG3
Machine:
TOS Kurim FUQ 150
Operation:
Rough boring 10xD, ø 39-51 mm
Tool:
Rough boring bar with integrated damper Seco-Capto™ C8, GPL=575 mm.
Cutting conditions: (Ø 40 mm)
Metric Inch Metric Inch
Cutting conditions: (Ø 50 mm)
Metric Inch Metric Inch
vc 138 m/min 453 sf/min f 0.008 mm/rev 0.008"/rev
vf n 230 mm/min 1100 rev/min 9"/min 1100 rev/min ap 2.5 mm 0.1"
vc 165 m/min 541 sf/min f 0.007 mm/rev 0.007"/rev
vf n 184 mm/min 1050 rev/min 7.2"/min 1050 rev/min ap 2.5 mm 0.1"
Insert:
CCMT09T304-F2, TP3500
Results
• Longer insert life • improved productivity
case 16: Multistep fine boring in casing (1) Operation:
Fine boring ø 120 H7 (2x), ø 110H7, and ø 145H7
Tool:
Fine boring head with 4 micro-units, with integrated damper, A=615.
Results
• The 4 bores are machined with a run-out under 20 microns
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case 17: Multistep fine boring in casing (2) Operation:
Multistep fine boring
Tool:
Multistep fine boring bars with aluminium bridge bars to achieve hole diameter quality IT6.
Results
• Improvement in productivity
case 18: square shoulder milling Material:
S355 (SMG3)
Operation:
Square shoulder milling
Machine:
WHN 130, SA50
Tool:
Steadyline face mill holder with R220.96-0080-08-7A, tool length 370 + spindle=560
Insert:
XNEX080608TR-M13
Cutting conditions:
Results
Metric Inch
Dc 80 mm 3.15"
zn 7 7
Metric Inch
fz vf 1540 mm/min 0.2 mm/tooth 60"/min 0.008 ipr
Metric Inch
n 1100 rev/min 1100 rev/min
vc 260 m/min 853 sf/min ap 1 mm 0.04"
ae 80 mm 3.15"
• Double depth of cut • Approximately 60% faster than previous solution
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case 19: examples of fine boring with steadylinetm Operation:
Fine boring up to 10xD
Tool:
Fine boring with integrated vibration damper to increase stiffness. Bodies made of steel or aluminium when overall weight reduction is needed, for larger boring bar.
Results
• Improvement in productivity, insert life time and surface finish
case 20: Deep internal boring with steadylinetm Material:
SMG 5 and 10
Operation:
Fine boring (ø 230H7)
Tool:
Boring bar with integrated damper, in aluminium with short and light head L=750 mm, 24 kg.
Insert:
DCMT11T304-F1, TP3500
Cutting conditions: Results
Metric Inch
vc 240 m/min 787 sf/min
fz 0.2 mm/rev 0.008"/rev
ap 2 mm 0.079"
• Surface finish • Productivity • Insert life time
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case 22: examples of multi-cut fine boring bars
Multicut milling holders
Operation:
Fine boring | Back boring
Tool:
Multi-step fine boring bars made of steel or aluminium, with micrometric units achieving hole quality IT6.
Results
• Improvement in productivity
Machining time: 10s. vs. previously 60s.
Combimaster
case 23: examples of milling holders with steadylinetm Shrinkfit
Operation:
Long overhangs on large, complex monolithic work pieces, deep cavities and difficult to access machining areas.
Tool:
Long milling assemblies (up to 10xD) with integrated damper to improve dynamic stiffness, insert life time, surface finish, and overall stiffness.
Results
• Improvement in productivity
Shell mill holders
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SECO TOOLS AB SE-737 82 FAGERSTA, SWEDEN TEL. +46 223 400 00 WWW.SECOTOOLS.COM 02863416, ST20136419 GB, © SECO TOOLS AB, 2013. All rights reserved. Technical specifications are subject to change without notice.
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