Custom Tooling - Winning solutions EPB

version 2013-1

Custom Tooling Winning Solutions EPB

HQ_BRO_EPB_Custom_Tooling_CS6.indd 1

7/4/2013 1:57:13 PM

2

HQ_BRO_EPB_Custom_Tooling_CS6.indd 2

7/4/2013 1:57:14 PM

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

3

HQ_BRO_EPB_Custom_Tooling_CS6.indd 3

7/4/2013 1:57:15 PM

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.

4

HQ_BRO_EPB_Custom_Tooling_CS6.indd 4

7/4/2013 1:57:17 PM

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.

5

HQ_BRO_EPB_Custom_Tooling_CS6.indd 5

7/4/2013 1:57:20 PM

wind power

6

HQ_BRO_EPB_Custom_Tooling_CS6.indd 6

7/4/2013 1:57:22 PM

7

HQ_BRO_EPB_Custom_Tooling_CS6.indd 7

7/4/2013 1:57:24 PM

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

8

HQ_BRO_EPB_Custom_Tooling_CS6.indd 8

7/4/2013 1:57:30 PM

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

9

HQ_BRO_EPB_Custom_Tooling_CS6.indd 9

7/4/2013 1:57:35 PM

agriculture

10

HQ_BRO_EPB_Custom_Tooling_CS6.indd 10

7/4/2013 1:57:39 PM

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

11

HQ_BRO_EPB_Custom_Tooling_CS6.indd 11

7/4/2013 1:57:44 PM

oil & gas

12

HQ_BRO_EPB_Custom_Tooling_CS6.indd 12

7/4/2013 1:57:47 PM

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

13

HQ_BRO_EPB_Custom_Tooling_CS6.indd 13

7/4/2013 1:57:57 PM

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

14

HQ_BRO_EPB_Custom_Tooling_CS6.indd 14

7/4/2013 1:58:04 PM

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

15

HQ_BRO_EPB_Custom_Tooling_CS6.indd 15

7/4/2013 1:58:07 PM

Automotive

16

HQ_BRO_EPB_Custom_Tooling_CS6.indd 16

7/4/2013 1:58:14 PM

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

17

HQ_BRO_EPB_Custom_Tooling_CS6.indd 17

7/4/2013 1:58:19 PM

general engineering & others

18

HQ_BRO_EPB_Custom_Tooling_CS6.indd 18

7/4/2013 1:58:23 PM

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

19

HQ_BRO_EPB_Custom_Tooling_CS6.indd 19

7/4/2013 1:58:31 PM

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

20

HQ_BRO_EPB_Custom_Tooling_CS6.indd 20

7/4/2013 1:58:34 PM

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

21

HQ_BRO_EPB_Custom_Tooling_CS6.indd 21

7/4/2013 1:58:37 PM

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

22

HQ_BRO_EPB_Custom_Tooling_CS6.indd 22

7/4/2013 1:58:40 PM

23

HQ_BRO_EPB_Custom_Tooling_CS6.indd 23

7/4/2013 1:58:41 PM

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.

HQ_BRO_EPB_Custom_Tooling_CS6.indd 24

7/4/2013 1:58:41 PM