GB EDGE Magazine 2011 #1

a magazine from seco #1.2011

perfect labels thanks to perfect holes

“It was a new and complicated design�

special tools for the a380 airliner since its introduction almost three decades ago, MinimasterÂŽ has been used by Scania to produce components for diesel trucks.

revolution the minimaster story

#2

how it works s t e a dy l ine™

good v ibes The Steadyline shell mill

holder increases machining quality and lowers costs in milling operations. Its vibration absorber dampens vibration and thus improves the dynamic stiffness of the shell mill holder, preventing it from chattering. Steadyline increases productivity, improves surface finish and extends tool life.

x2–4

2–4 times higher productivity than with conventional shell mill holders

Central coolant tube to feed coolant to the cutting edge

30/50%

Vibration absorber positioned as close as possible to the cutting edge, where displacement is the highest

in a copy milling test, performed 30% faster with a 50% longer tool life than competitors

www.secotools.com/steadyline Product availability: NOW Order & application data: Machining Navigator 2011

Edge is a customer magazine from Seco Tools.

It is published in 25 languages worldwide.

Seco Tools AB Marketing Departement, 737 82 Fagersta, Sweden. Phone +46 223-400 00 Fax +46 223-718 60 Internet www.secotools.com Publisher Paul Löfgren E-mail paul.lofgren@secotools.com

Managing editor Jennifer Hilliard ­ E-mail jennifer.hilliard@secotools.com Editorial production and layout Appelberg Publishing Group Project manager Per-Ola Knutas Art directors Cecilia Farkas, Johan Nohr Print PA Group Karlstad Coverphoto Stefan Almers/Scania

Editorial material in this publication is the copyright of the publisher, Seco Tools AB. Articles may be reproduced free of charge providing reference is made to Edge and the Managing Editor is notified. The trademarks and brand names used in this publication are protected by law.

con t en t s e di t ori a l #1.2011

10

Aircelle requires custom tools for the advanced composite materials in airplane components.

a tool for

every job in your hands you hold the first Edge of 2011, an

04 08 10 14 18 21 24

Industry: filling and packaging

Krones has been making labelling machines since 1951. Today, production takes advantage of Xfix™.

products: power 4™

The power generation industry gets higher performance with the Power 4 copy milling cutter. materials: carbon composites Aviation supplier Aircelle works with Seco to develop

customised solutions to specific tasks.

appealing introduction to Seco’s latest high-performance products and services. We are passionate about our extensive offerings, of course, but we are also passionate about our customers – which is why we are so eager to showcase their successes in our magazine. These case studies, supported by firstclass photography, examine innovative solutions that focus on specific components.

I regularly get e-mails from you praising Edge’s technical articles. This issue follows suit – for example, see Patrick de Vos’ “Insight” column (page 17) on what to watch for in a cutting edge. We also take an in-depth look at Power 4 on page 8.

I recommend taking a look at our article on page 26 about our Customer Interface applications, as well. They enhance the performance of our products and make it easier for you to work with Seco. The applications range from product and cutting-data configurators to e-commerce solutions.

With these and other stories, we hope that our magazine continues to be an enjoyable part of your day. paul löfgren senior vice president, group marketing edge@secotools.com

application: MDT

Multidirectional turning technology is helping MAE in New Zealand create moderators for firearms.

Profile: tracie clarke

Seco’s Manager of Strategic Programs in North America shares her story. products: minimaster

The Minimaster revolutionised end milling in 1983, and the Minimaster Plus aims for the same. on the job: Michael Richardson

Advanced Cutting Tools Ltd’s managing director tells about Seco’s Productivity & Cost Analysis (PCA).

edge [1 � 2011]

03

INDU STRY F ILLING AND PAC K ING

Xfix

hole heart

Seco’s Xfix is a range of reamers for large-diameter holes (39.5–154.5 mm). The striking gold-coloured, TiN-coated head has a number of inserts (3, 5, 7 or 9), each with 8 cutting edges, ensuring precision to IT6 tolerance and accuracy. Guiding pads keep the reamer stable, and the run-out is controlled by a ring which can be adjusted to an accuracy of less than 3 microns. www.secotools.com/xfix Product availability: NOW Order & application data: Holemaking Catalogue 2011

04 edge [1 �2011]

ted

Labelling machines require perfect holes in order to work properly. Xfix reamers are helping improve accuracy at the production line at Krones.

Text Michael Lawton Photo Martin Hangen

I

f you’ve held

more than three bottles this year, the statistical likelihood is that you’ve handled a bottle that has gone through a machine made

by Krones. The world’s market leader in filling and packing technology, the company makes machines that handle millions of bottles, cans and other containers every day.

Over the years, Krones has developed into virtually a onestop shop for the drinks industry—you can, for example, buy a complete brewery from them, from the building permit to the brewing tanks to the bottle-recycling logistics at the end (simply add hops and barley). The company can also make you production lines that fill bottles of tomato ketchup, for example, or label toothpaste tubes or cat food.

They’ll design a bottle that expresses your brand, and make the machine that turns a plastic preform into the bottle of your dreams. They even offer bottle washing machines.

The company has five factories in Germany that supply the world via approximately 80 sales and service centres. edge [1 � 2011]

05

INDU STRY F ILLING AND PAC K ING

Wolfgang Gottschalk heads up one of Krones’ five production units in Nittenau, Germany.

The main factory in Neutraubling, in northern Bavaria, makes machines for filling, labelling, inspection, transport and plastic stretch-blow moulding. A second factory in nearby Nittenau provides components and modules for the machines.

The remaining three plants provide additional products to complete the Krones range.

The company started in 1951 with labelling machines, and, as Wolfgang Gottschalk, head of one of the five production units in Nittenau, says, “Our expertise has been built on the back of our labelling machines. Labelling is particularly important for a manufacturer, because labels show how a brand positions itself in the market – so they have to be good.”

Longer tool life Component: Mould plate Operation description: Reaming Machining objective: Correct hole quality (H6 and M6 tolerance) & reduction in machining time Machine tool: Machining Centre Tool clamping: HSK-A arbors Material: Cast Iron (GGG60) Cutter/Tool: Xfix reamers diameter 42+65 mm (2 different tools) Cutting data: vc: 80-100 m/min f: 0.25 - 0.3 mm/rev Result: Tool life > 200 minutes

06 edge [1 �2011]

The heart of every labelling machine is the unit that actually sticks the labels onto the bottles. As the bottles pass by, a curved plate carrying the glued label rolls across, leaving the label behind. The applicator plates are mounted on shafts that are themselves mounted around a platter. As the platter turns, each of the eight shafts carrying the plates turns to face the bottle line, and is then withdrawn to receive the next label. The process happens at a dizzying speed: Krones machines are designed to label up to 72,000 bottles or 120,000 cans an hour.

Xaver Ram, head of the production team that makes the platter, says it’s essential that the holes in which the shafts are located are exactly dimensioned. “We need accuracy of a few microns in the diameter and less than two hundredths in the position of the hole,” he notes. “Otherwise the shaft doesn’t run true, and the applicator plates don’t touch the bottle surfaces precisely enough.” That can mean that labels may not sit accurately, or that more glue is required.

Each platter has eight holes, and each hole used to be finished with a fine boring head.

Manuel Schmid is one of the three skilled craftsmen who operate the machine that makes the holes. He says, “You would have to check after every second hole whether the size was still right. If the measurement was wrong, you had to readjust the fine boring head and maybe operate the hole again.” As a result they only produced two or three platters per shift.

Krones turned to Seco; as Gottschalk says, “We have a long history of working together on solving problems and optimising processes.” And Ram adds, “We have a lot of metal cutting companies here, but Seco is one of the our main suppliers.” As Krones has grown, its relationship with Seco has grown, too: It now has Seco’s full product range throughout its production, and Krones is keen to cooperate on developing new solutions.

So when regional representative Gerhard Huber heard that Seco had developed a new kind of reamer that was ready for testing, he thought that Krones would be the right partner.

“Most reamers only have one cutting blade, but Xfix has several, meaning that it’s more accurate and faster,” explains Huber. “It also has special features to make it more stable in the process.”

Krones’ platter problem was precisely what Xfix was designed to solve, so Krones was selected to field test an Xfix. Ram says, “We only have to set the reamer up once, and that will last for ten to fifteen platters.” Although it does take more time to set up the unit, the process takes 15–20 percent less time. Operator Schmid says, “There are five inserts to adjust instead of just one – but once it’s set up, it lasts a lot longer.”

Gottschalk says, “The main thing for our customers is that the process should be secure and that the quality should be right. If we can save some time in the production, that’s a very welcome side effect.” edge [1 � 2011]

07

PROD UCTS POWER 4

Power 4 All Text Graeme Forster PHOTO BIM/Istockphoto and Seco

manufacturing turbine blades is tough. So to help

provide the best machining results, Seco has introduced Power 4, a new copy milling cutter. The tool was developed in cooperation with key Seco customers to ensure that it has the precise qualities needed by the power generation industry.

“We often see heavy workload conditions for machining turbine blades,” says Emilio Scandroglio, International Application Expert in Power Generation at Seco. “So we always have to consider applying the strongest and most reliable solution, starting with the right machining strategy and an appropriate cutting tool. We discussed this problem with our customers, and together we came up with Power 4.”

The unique anti-rotation system gives the tool maximum stability. It features four facets on the insert clearance side and facets at matching locations on the pocket seat. The facets prevent the inserts from rotating during machining.

Also, the facets allow safe and easy insert indexing, simplifying set-up for the operator.

The patented pocket seat has a maximised contact area between the insert and the body, adding reliability and stability. To maintain the tight tolerance needed for high-quality machining, the seat pocket is sealed to keep chips and dirt from getting inside; this eliminates the need for flushing before or after use. Moreover, the chip room is designed for optimum chip evacuation.

To avoid wear and oxidation problems, all cutter bodies have a nichrome coating with an exceptionally high surface hardness. Power 4 is available with insert sizes 10mm and 12mm, with various insert grades and geometries.

08 edge [1 �2011]

ou t l ook global trends

Trends that impact raw material prices

Raw material prices have recovered following a major drop in connection with the financial crisis. So what can we expect in the future? Edge asked Mattias Erlandsson, division head for international and financial economics at the Swedish National Institute of Economic Research, to list five key long-term trends that impact raw material prices. text Ylva Carlsson illustration Johan Nohr

2

3

Supply of raw material

“If global growth accelerates, there is a risk of bottlenecks forming in the production of certain raw materials, which could force prices up. Production disruptions such as crop failure could generate temporary price increases for agricultural products.”

4

Oil prices

“Crude oil is the most important limited raw material in the global economy.

According to our forecast, oil prices will increase somewhat in the short term, but not much higher than USD 100 per barrel.

The assessment is based on the supply of oil being sufficient to cover consumption in the coming years.”

1

Global gross domestic product (GDP) growth

“Higher growth generates higher raw material prices. Our forecast for the coming years shows that global growth will be in line with the average in recent years, and that raw material prices will rise somewhat. However, there is a risk of weaker growth, since several large industrial countries will have to reduce their deficit by increasing their savings.”

Energy prices

“There is political will, particularly in the EU, to convert to more renewable energy. At present, it is impossible to say what a new energy mix would be, but it is probable that the price of energy – relative to other production factors – will increase for a period.”

USD trend

“The global economy is in a state of imbalance since the US, in particular, has a major deficit in its foreign trade, while several Asian countries have a major surplus.

A weaker dollar would contribute to reducing the imbalance and lowering the risk of new financial crises.” edge [1 � 2011]

09

MATERIALS ca r b o n co mp o si t es

A cut above

Aircelle needed tools that could handle a single, long cut through state-of-the-art materials for the A380 airliner. Seco came through with a tailored solution.

Text Anna McQueen Photos Jean-François Rollinger/ANA

10 edge [1 �2011]

photo: istockphoto

The high-tech materials that Aircelle uses are notoriously difficult to machine.

Cut into the matrix New composite materials consist of two or more different materials bonded together, forming a strong, stiff ‘matrix’ in which fibres or particles are embedded. More and more of them are being used in the aerospace industry because of their high strength-to-weight ratio, good corrosion resistance and low thermal expansion.

These state-of-the-art composites are more difficult to machine, increasing demand on cutting tool function and performance and raising the standards for hole and edge quality.

Seco’s brand-new Jabro™ Composite (JC) range of milling tools is perfect for Aircelle’s precise milling needs, providing an extended tool life with higher speeds and greater cutting precision.

These solid carbide end mills have a CVD diamond coating to reduce wear and prolong tool life.

The Jabro Composite range offers minimum component delamination and splintering with maximum resistance against vibration. It’s perfect for burrless machining, side milling and 3D copy milling, contouring and slotting of materials such as layered carbon-fibre and glass-fibre composites, high performance engineering plastics and honeycomb materials. www.secotools.com/jc Product availability: NOW Order & application data: Tools for advanced and modern materials.

The Solid End Mill catalogue will be available March/April.

N

ow a subsidiary of French defense and aerospace conglomerate SAFRAN, Aircelle was founded in 1896 to produce armaments in the Normandy port of Le Havre. Since then it has grown to be a leading player in the global market for nacelles (covering components of aircraft), with a workforce of 3,000 producing nacelles, thrust reversers and aerostructures. The company is a key supplier to the Airbus A380, the largest passenger airliner in the world.

Aircraft designers are constantly pushing the boundaries, developing ever-lighter, stronger and more resistant materials to allow their planes to fly faster and further with heavier loads – whilst economising on fuel. The compositecarbon and carbon-sandwich materials used by Aircelle for the A380 are very difficult to machine; it takes state-of-the art tooling solutions to guarantee the required precision.

“In 2006, we decided to upgrade our production facilities with an advanced, five axes milling machine for cutting large composite pieces,” explains Julien Boulet, Programming Technician at Aircelle. “The part it cuts for A380 nacelles have a linear cut of up to 12 metres. To get the very best out of the machine, we needed the right cutting tools, so we challenged all our tool suppliers with samples of the composite material,” says Boulet.

The workpieces are made up of two materials: a 12mmthick carbon-fibre composite and a 40mm-thick carbon honeycomb composite. “We wanted to find a solution that could cut through in a single pass with a single tool, thus saving a lot of time and money,” says Amory Langrene, ComputerAssisted Manufacturing (CAM) and Automation Manager.

“Moreover, this faster cutting solution had to maintain the edge [1 � 2011]

11

We wanted to find a solution that could cut through in a single pass with a single tool.

integrity of the composite and provide us with a highquality cutting edge – and all this in a cost-effective proposal.”

After considering the various proposals,

Aircelle opted for a customised version of Seco’s Jabro tools in December 2007, going into production shortly afterward. “Seco worked closely with us to come up with the right solution, and with their tailormade Jabro tools, we’re cutting pieces up to three times faster than before,” says Boulet. “With a single, high-quality cut that is consistent for up to 16 meters, we’ve increased our production without having to invest in another machine.”

Langrene says, “For me, a tool supplier must be available and reactive, but most importantly they need to be able to respond to our specific needs.

Many tool suppliers offer a standard range that works everywhere – but that, in reality, works nowhere. We need partners who can come onboard in a research capacity and work with our CAM team to develop the right solution that meets our specific needs. With Seco, we have that kind of relationship, and we’re planning to take it to other areas of Aircelle’s production in the near future.”

12 edge [1 �2011]

Seco worked with Aircelle to develop customised tools for specific tasks.

No burring on component Component: Aircraft engine covers Operation description: Slot milling Machining objective: Machining distance 4000 mm, no burring on component Machine tool: Machining Centre Tool clamping: High precision Shrinkfit holder Material: Carbon Fibre or Carbon FibreAluminium composite Cutter/Tool: JC860 Honeycomb router cutter, diameter 10mm, Dura coating Cutting data: vc: >150 m/min vf: 300 mm/min ap: > 35 mm ae: 10 Coolant: Dry machining recommended Component: Aircraft engine covers Operation description: Routing Machining objective: Machining distance 16000 mm, no burring on component Machine tool: Machining Centre Tool clamping: High precision Shrinkfit holder Material: Carbon Fibre composites Cutter/Tool: JC871 Honeycomb router cutter, diameter 10mm, Dura coating Cutting data: vc: >300 m/min vf: 1500 mm/min ap: > 10 mm ae: 10 Coolant: Dry machining recommended

Susta i na b ility

The heat is off

Seco’s new production facilities in Sweden use the latest in energy-efficient technology, just one example of the company’s ambition to minimise its impact on the environment.

Text Per-Ola Knutas photo Istockphoto

In all its production and product development,

one of Seco’s aims is to reduce environmental impact. The latest case of this is at the company’s newly opened production facility in Fagersta, Sweden, where the new building is virtually self-supporting in terms of heating and cooling.

“The new humidity-based system uses excess heating from compressors and sintering furnaces – rather than electricity – to maintain the indoor climate,” says Gunnar Lobell, Global Environmental Coordinator.

In a separate initiative, Seco cooperates with the local district-heating company, sending out waste heat from production to the heating network in Fagersta.

“This way, not only are we contributing to sustainable development, we are making a positive contribution to the local community,” Lobell says.

Seco has overall environmental targets aimed at reducing the environmental impact from waste, chemical products, energy consumption and transport. The tool being used to achieve this is a common environmental management system, certified according to ISO 14001 in 2006 and introduced in 20 of Seco’s facilities in 13 countries.

“The certification process means that we made an extremely thorough mapping of our environmental impact,” says Lobell. “It involves in-depth environmental studies, training of employees and clear routines. As a result, the environmental impact and the risk of environmental accidents have been reduced.”

In product development, Seco always strives to make its products more and more efficient.

sustainable goals Seco’s priorities for the future: Recycle 50 percent of all delivered carbide products by 2014 (used inserts and solid cemented carbide tools can be sold back).

Increase energy efficiency (electrical energy, heating energy, vehicle fuel) by 5 percent every year.

Decrease the amount of waste per ton from production by 2 precent every year until 2012, and increase the amount of recyclable waste from 55 percent to 60 percent.

Decrease environmental impact from chemicals. Reduce substances of very high concern by 5 percent per year.

Decrease environmental impact from transport. Implement reporting for CO2 emissions from shipping and continue monitoring emissions from business travel.

“This has clear environmental benefits for customers; increased productivity means that workshops process more material with less energy,” says Lobell.

Seco stepped up the company’s recycling programme in 2010; customers in all markets can now sell back used inserts and solid cemented carbide tools. The long-term targets are ambitious; for example, by 2014 the goal is to recycle 50 percent of all the carbide products Seco delivers. edge [1 � 2011]

13

APPLI CATION m dt

14 edge [1 �2011]

MAE uses multidirectional turning (MDT) tools to profile internal moderator parts.

Out of earshot

Text Diana Clement Photos Derek Cook and Image Source

Firearms damage their users’ hearing, but a New Zealand company has developed moderators as a mainstream solution for noise reduction.

A

sk MAE founder Gary McColl

what his New Zealand-based company manufactures, and he’ll tell you, “noise-control products.”

Firearm moderators, or “silencers,” may have a bad name in popular culture, but they’re an essential health and safety tool for hunters, pest control staff, police and army personnel.

Every shot from a firearm exceeds safe noise limits. The moment the firing pin (striker) impacts the primer to the igniting powder in the firearm’s barrel, gasses fire forward two to three times faster than the bullet itself, sending out a blast capable of damaging the human eardrum.

MAE moderators deal directly with the energy produced from a gunshot, reducing the noise, with sometimes dramatic benefits. For example, McColl says that soldiers can continue to hear what’s happening around them as they fire – a significant safety improvement in a dangerous job.

New Zealand’s wild animals (such as deer, pigs and goats) are confused by firearms fitted with moderators, as they cannot detect where fired bullets originate. The impact of a bullet behind an animal is often the first thing it hears – sometimes sending it running straight towards the hunter.

MAE customers have reported other unexpected results: One had a hunting dog that recoiled at the sound of gunshot. Now, the dog pricks its ears up when the bullet is fired and leaps into action to do its job if it hears the bullet hit the target.

When McColl, who has more than two decades of experience in firearms-related businesses, bought the business (previously called Percy Engineering Services), it was little more than a cottage industry. He planned to automate with CNC machines as soon as possible to refine the product and increase volumes. Thanks to advice from Trade Tools Limited, a major New Zealand distributor of Seco Tools, MAE began using Seco

We can program a job with confidence, knowing it will complete the run without any issues.”

Gary McColl, founder, MAE

edge [1 � 2011]

15

APPLI CATION m dt

Jetstream Tooling The next generation of cutting tools use Jetstream technology, which delivers coolant to the cutting edge. Developed by Seco for the aerospace industry, the technology removes the heat from the cutting zone to enhance cutting tool performance. www.secotools.com/jetstreamtooling

products even before it automated. Ian Langley, Seco Tools regional manager for New Zealand, supported and advised MAE throughout its transition from manual to automatic production, making Seco the natural first choice for McColl when choosing tools for his new CNC lathe.

MAE invested in multidirectional turning (MDT) tools, Crownloc® drills, SD insert drills and Quattromill® cutters (all are held with EPB back-end tooling). The MDT technology is used to profile internal moderator parts, typically for grooving and thread run-out. According to McColl, the real competitive advantage of an MDT tool in a 12-station turret is that it takes up only one position instead of three. “It means we can add a few extra tools because we have the space,” he says.

McColl adds that Seco’s MDT tools also last longer, are stocked locally, and have better rigidity and superb insert location. “We can program a job with confidence, knowing it will complete the run without any issues. We get longer tool life, achieve guaranteed repeatability and increase the number of components per edge.”

It wasn’t, however, plain sailing; McColl broke four MDT tools in a short period of time. He tried various competitors’ products, but found them to be inferior to Seco’s. Happily, the company hasn’t broken a single MDT tool since then, and McColl is looking forward to upgrading to MDT Jetstream Tooling™.

16 edge [1 �2011]

Sales manager Stu Beresford demonstrates a newly manufactured moderator.

MAE’s moderators reduce the noise from gunshots, sparing the hearing of hunters, police and army personnel.

Crownloc tip drills The first drill with completely exchangeable crowns, Crownloc includes a wide range of optimised tip geometries for different applications. Its benefits include a lower cost per cutting edge, no regrinding costs and a consistent tool life. The cost-effective exchangeable tip drills increase productivity, flexibility and hole quality. www.secotools.com/crownloc

Quattromill For high-performance face milling in virtually all types of materials and machine tool sizes, Quattromill is armed with highly positive square inserts that give depth-of-cut capabilities up to 6mm.

Quattromill is ideal for demanding applications and situations with difficult work holding and poor component stability. www.secotools.com/quattromill

Duratomic® turning The TM2000 stainless steel Duratomic turning grade used by MAE is the first choice for high productivity in stainless steel machining applications. It features Duratomic coating technology, which provides wear resistance and edge toughness. www.secotools.com/duratomic

INSIGHT m ach i ni ng a b i lity

The edge whisperer Patrick de Vos, Corporate Technical Education Manager at Seco Tools Group, explains how the cutting edge tells you that it’s time for a change.

A cutting edge has a hard life.

With today’s workpiece materials and cutting conditions, it’s heavily attacked from all sides – mechanical loads! Chemical attacks! Thermodynamic assaults! Modern cutting materials (such as Duratomic coated carbide grades) combined with the correct tool geometries can handle it all, but they, too, will wear out at some point.

In earlier days tool wear was rather easily observed, as it was mainly flank wear and crater wear.

The wearing process could easily be followed (the S tool wear curve), and the operator could in due time stop the cutting process and change the cutting edge.

Today it is much more difficult.

The cutting edge will look like new for a long period, and then suddenly – it breaks!

A broken cutting edge can cause large production stops. We all know about “disaster tourism” in the workshop – everybody needs to give an opinion, and in the meantime machine tools are not producing.

Understanding tool wear and the mechanisms causing it is fundamental to controlling the cutting

process for high-quality workpieces. This understanding will help you to correctly modify the input conditions – selected tools, cutting strategies, cutting conditions – to improve the output in whatever direction you want: higher productivity, lower costs, higher process security, etc.

Of course, the trick is to stop the operation one second before the cutting edge breaks. And there are signs for when that’s going to happen: Can you see the “grey zone” on the cutting edge, for example? The very subtle chipping and crumbling? The slightly changed shape and colour of the chips?

If you watch out for these signs and others, the cutting edge will clearly tell you when the time has come for a change – and use some help, such as a small tool-wear magnifying glass. (Sorry, but metal cutting is a high-tech business that requires scientific observation, not just “a feeling.”) Duratomic grades can easily double tool life, but it takes a metal cutting professional to get the most out of them. And don’t try to wait for the last 10 seconds of tool life – that’s false thrift!

Doing so just creates broken cutting edges and process insecurity.

In the Seco Technical Education Programme (STEP) we developed an in-depth module in which we link tool wear to typical workpiece material properties, so you know what to look out for in different workpiece materials. I recommend talking with your local Seco representative to learn more about our STEP programme.

Seco can give you the knowledge on how to handle tool wear. Higher, more economical production will be your reward – good luck!

Patrick de Vos, patrick.de.vos@secotools.com

Four signs a cutting edge is about to break:

Chip colour

Chip shape

Burring

Cutting power

edge [1 � 2011]

17

port r a i t t r ac i e C l a r k e

Making Tracie Clarke’s compelling journey at Seco has taken her from working shifts on a shop floor in England to the company’s North American headquarters in Detroit.

Text Linas Alsenas Photo Eric P. Mull

T

racie Clarke, Seco’s Manager

of Strategic Programs, knows from experience what it means to be the only woman in the room.

A native of England’s Worcestershire County, Clarke began a four-year technical apprenticeship in 1988 at Rolls-Royce Allen Gears Ltd, formerly NEI Allen Gears Ltd, a firm that manufactured power equipment for the marine industry.

“There were 200 to 250 guys, and me,” says Clarke. “They even made me wear different coloured overalls, just so they could keep an eye on me. I was so angry – I had to wear blue, and the rest wore green overalls. I started off being the alien.”

But Clarke persevered, working just as hard – and sometimes harder – than the men around her. “And truth be told, the heavier work was more difficult for me,” she says. “I had to use cranes to handle the heavier loads, and there were parts I couldn’t reach, so I had a small ­step ladder. There was a lot of skepticism.”

18 edge [1 �2011]

Considering the enormous challenges she faced, what drove her to take on this line of work?

“I wanted to be the best engineer I could be,” Clarke says, “You know, the feeling that I made something. I actually made that. And we’re not talking about a lump of metal; we’re talking about a high-tolerance part that is critical.”

In the end, Clarke’s performance and personality earned her the respect of her colleagues. By 1996, she was ready for a change, and she moved to Seco Tools in Alcester as an operator. “Seco at the time was going through a lot of transition,” she says. “They were introducing 5-axis mills and new programming, pushing out the old machines and bringing in new ones. I did four years, and I loved it.”

But from the start, Clarke had set her sights higher. Her manager, Mike Parker, was aware that she had been attending evening classes in order to learn design and drafting work. “I reminded him constantly that I was ready for the Drawing Office, and in 2000 he offered me the job,” she explains. “Of course, I jumped on it.

“ I’ve always wanted to be that girl with the toolbox who goes around and fixes things.”

nerves of steel Name: Tracie Clarke Age: 38 Background: After completing her apprenticeship, Clarke worked full-time as a CNC operator for four years at Rolls-Royce (which had acquired Northern Engineering Industries) before coming to Seco Tools in Alcester, England, as an operator/2nd programmer for CNC milling.

Four years later, she switched to design work, but soon switched again, this time to sales. Clarke was appointed regional sales manager in 2004, and she remained in her position for six years. During that time, Clarke participated in formulating Value Based Selling (VBS) at Seco and was chosen for the company’s Talent Development training course. Clarke moved to Detroit in 2010 for her current position as Manager of Strategic Programs.

Outside interests: Clarke is an accomplished scuba diver, having been certified as a rescue diver by the Professional Association of Diving Instructors (PADI).

edge [1 ďż˝ 2011]

19

port r a i t t r ac i e C l a r k e

There would be no more dirty overalls, I would be in trousers and office clothes… but nine months later, I was out. I absolutely hated sitting at a computer all day; it just wasn’t for me.”

Instead, Clarke was given the opportunity to shadow a salesman for two weeks, and she quickly came to a realisation: “Customers called us with engineering challenges. These sales guys had the technical training, and if they figured out the problem, they established a relationship. I thought, whoa. That’s what I want to do.”

Clarke took on fifty small customers, and within a year, she was asked to cover the whole region. “I was good at this,” she says. “I got to get back into my overalls and go out to customer shop floors. I’ve always wanted to be that girl with the toolbox who goes around and fixes things.”

But again, Clarke was the only woman in the field – at least, on the technical side – and she had to earn the respect of customers. “At first, with some of them, it was a nightmare. I had a guy open the door, look past me, and say, ‘I’m sorry, but I called Seco for an engineer, not a woman.’

This happened five or six times, but they would soon realize that I knew my stuff and could help them. Being a woman didn’t seem to matter once they knew they could depend on me.”

Despite her challenges, Clarke excelled.

She won Business Manager of the Year in 2002 and 2003 – a remarkable feat, considering that growth is an important criterion. Clarke credits Seco’s new way of working with customers, which focused on close partnerships.

In 2004 Clarke was soon asked to apply for

a regional manager position, but she wasn’t sure she was ready. “I’m only 32 years old,” she answered, “I’ve been in sales for four years, and you think I can be regional manager? Not only am I the youngest person, I’m the only woman.”

But in the end, she decided to take the leap, and she held that position for six years, until 2009.

“We had some exceptional years. We had a solid team with good customers.”

Today, as Manager of Strategic Programs, Clarke’s position in Detroit makes her responsible for all of Seco’s international and national accounts within the NAFTA market, including GE, Volvo, Siemens, Stryker and Rolls-Royce. She is also responsible for Seco Business Solutions, the

20 edge [1 �2011]

Tracie Clarke’s tips for women in the industry: It doesn’t matter whether you are male or female; just know your product, and use your experience.

Common sense goes a long way when dealing with customers who need solutions.

“ I wanted to be the best engineer I could be.”

Never pretend to know something you don’t. Trust is the key to strong business relationships.

People buy from people – understand your customers’ needs, and deliver winning solutions.

Pricing Intelligence group and the development of a full partnership package for NAFTA. Moreover, Clarke is overseeing the knowledge transfer from the UK for the new Rolls-Royce Crosspointe Facility in Virginia.

Lou Novacco, Director of Sales, says, “Tracie spares no effort in treating customers with the utmost care and attention, and they respond in kind. She can hold her own in any technical discussion with a customer, which is a prerequisite to establishing the right level of respect.”

“Yes, I’ve worked hard,” Clarke says, “and yes, it’s been tough, but I’ve also been very fortunate.

Now I’m just thinking, ‘Hey, I’m here, I’m living it.’ And time is just flying by.”

products minimast e r plus

When Minimaster entered the milling scene, there had never been anything like it. The story of the category-creating milling cutter begins in 1983, just before vacation… text Åke R Malm photo Jonas Gauffin

Bengt Strand came up with the idea for Minimaster back in 1983.

The Minimaster

story Just three days before his summer vacation, Bengt Strand, a product developer at Seco’s Fagersta plant in Sweden, needed to mill a prototype of a new milling insert. Unfortunately, the person in charge of geometry verification machining had already taken off for his annual leave. So, Strand decided to use a regular milling machine instead to validate the new insert shape.

To manage that, he had to make the prototype

insert ten times its real size and use a solid end mill to machine the new insert.

“It took me almost five hours to mill the insert prototype,” he says. “So I had plenty of time to figure out how to make an end mill with replaceable heads instead of using a solid end mill that needs to be completely removed when changing the cutting edge.”

His challenge was to design a tool for copy edge [1 � 2011]

21

products m inim ast e r p lu s Stefan Almers/Scania

Since its inception, Minimaster has been helping produce components for Scania’s diesel trucks, including gear-boxes and engine blocks.

milling that could compete with solid end mills (the only solution available in 1983) and that didn’t require any small exterior screws to fix the insert. The following day he had thought it through and was ready to make a prototype from an ordinary solid end mill.

“On the third day I tested it, and it worked really well,” Strand remembers. “I just wanted to try my idea, so I could at last go on vacation.”

Back at work again, he sought the support of his boss, Sven Eklund, who helped develop a technical solution for fixing the insert to a shank.

After testing a number of options, they settled on a tapered design that connects to an interior tension screw in the shank, thereby avoiding any small exterior screws. Design engineer Calle Berglöw got to work on the drawings, and eventually they were ready to press the first real insert. At that time most inserts were flat, so pressing it was a challenge.

“It was a new and complicated design, and only one person in the process lab volunteered,” says Strand. “His name was Bertil Lundberg, and without him we would not have the Minimaster today.”

In other words, he succeeded, and a prototype was made.

“When the insert had been pressed, we showed it to the CEO at the time, Jan-Erik Forsgren, who got really excited about it,” says Strand.

Then it was full steam ahead, and in 1987 the first Minimaster series was released. The rest, as they say, is milling history. During its 23 years on the market, the Minimaster has been produced in many different versions and in large quantities.

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Christer Jönsson, Jörgen Andersson and Tapio Alatalo (left to right) are leading the effort for Minimaster Plus.

Minimaster Plus Increased productivity and precision Flexible mix of inserts and shanks Internal cooling channels Two-, three- and multi-flute inserts Suitable for machining all kinds of workpiece materials www.secotools.com/minimasterplus Product availability: May Order & application data: Minimaster Plus catalogue

We had to start from scratch with more or less all our production processes.”

The next generation With the launch of Minimaster Plus, copymilling technology takes another leap forward. A new insert design offers higher productivity and finer tolerances with the same flexibility as its renowned predecessor. text Åke R Malm

the challenge facing Pre-study Manager Christer Jönsson and his team wasn’t an easy one: Develop a new generation of Seco’s successful Minimaster series. Since its 1987 launch, Minimaster had taken a lead position in endmilling systems with interchangeable carbide inserts – in fact, it created the category. But the company felt that increases in commercial and technical demands would eventually require radical change in copy milling technology.

“We had to develop a concept that was on par with solid end mills in terms of price and precision,” says Jönsson, who is now Corporate Prod-

uct Manager for Milling. For example, when a used insert is replaced with a new one, the axial and radial position should remain the same for maximum precision. It should also be possible to replace the insert without removing the shank and re-measuring the whole assembly.

Jönsson and his team of specialists started by listing technical solutions that could address these issues. The list came to seventeen ideas.

They boiled those down to ten, and then to three. Eventually, only one was left: a replaceable carbide insert with an internal thread and an external taper. The shank had an internal taper with a threaded centre pin, plus a new feature: an axial stop. This would keep the position of the insert within the required tolerances.

The specification landed on Project Manager Jörgen Andersson’s desk for hands-on product development and adaptation for serial production. He and his colleagues made a few prototypes based on Minimaster geometries to verify that the system matched the specifications. It turned out to be a difficult case.

“We had to start from scratch with more or less all our production processes,” says Andersson. “The ones that we had just weren’t up to the standards required to make this product.”

This transformation included reconsidering everything from the powder mix used for pressing the inserts to the grinding machines that sharpen them. Eventually, Minimaster Plus was ready for lab tests. At the end of 2010 it underwent field tests in cooperation with selected customers, and it will be released in May. “Minimaster Plus will be launched in three steps,” says Tapio Alatalo, Product Manager Copy Milling. “First we will release a core programme, to be followed by an extended selection of inserts and shanks in two steps.”

Users of Minimaster need to get new shanks to benefit from the additional precision and productivity offered by Minimaster Plus. edge [1 � 2011]

23

on the jo b

photo Mishka Henner

MICHAEL RICHARDSON Age: 39 Occupation: Managing Director, Advanced Cutting Tools Limited Location: Gateshead, UK Family: Wife Interests: Mountain biking in Scotland and Kielder, England

Everybody wins Michael Richardson, Managing Director of Advanced Cutting Tools Ltd, takes advantage of Seco’s PCA programme to improve his customers’ bottom line.

We’ve been around for

over five years, and we’ve been distributing Seco products for about four and half. For the past couple of years now we’ve been using Seco’s PCA (Productivity & Cost Analysis) to demonstrate to our end-users what advantages can be gained from Advanced Cutting Tools and Seco’s tooling expertise.

How it works is this: we identify production areas – or the customers inform us – where it might be possible to reduce costs and increase productivity in production. These are places where the tools need to be replaced often, for example, or the production isn’t fast enough.

Seco’s local engineer visits the customer to reengineer the jobs. That person will watch the process and come up with ideas for improving the cost of production, usually new tooling solutions that are out in the market. A trial is put together to demonstrate the suggested tooling, and we record that data – speed, feed, costs, prices, etc. – that we present to the customer.

It’s very rare, maybe once out of a hundred times, that we don’t find improvement. With PCA, the customer has nothing to lose, and the savings can turn out to be as much as 50 percent! And the whole process takes only one or two weeks, depending on the customer’s production schedule.

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Productivity & Cost Analysis (PCA) Seco’s PCA system takes a wide view of customers’ manufacturing, focusing not just on tooling costs but the total cost of production. Seco engineers can evaluate a single machine tool process or the complete path a workpiece takes in a manufacturing plant.

PCA software provides a comprehensive report with process information such as tooling and cutting data. It also provides data such as cost per part, output per hour, tool consumption and investment cost. www.secotools.com/PCA

in brief

www.secotools.com Product availability: NOW Order & application data: MN Update 2011

Un a l l oy ed succes s wi t h a l l oy s For superalloys and titanium alloys used in the aerospace, energy and medical technology industries, highperformance profiling requires special tools. That’s where RP chipbreakers come in, the latest addition to Seco’s multidirectional turning (MDT) product family. RP chipbreakers have peripheral ground edges to ensure high surface finish and extended tool life, and the inserts’ special open-groove geometry ensures cleaner chip removal. The edge and groove designs also make the tools perfect for machining non-ferrous materials and aluminium alloys. RP chipbreakers are supplied in the most common sizes from 3 mm to 10 mm, and their performance can be further enhanced with Jetstream Tooling high-pressure coolant. www.secotools.com/ rp_chipbreakers

Text Graeme Forster

Small wonder MDT 2mm expands the capabilities of Seco’s multidirectional turning (MDT), grooving and parting-off range. This new, smaller size (the present lineup ranges from 3mm–10mm in width) gives customers the opportunity to turn, groove, profile and part off in a wide range of general machining

operations.

MDT features the unique Secoloc insert clamping method.

During operation, maximum stability is ensured by a combination of a V-top clamp and serrated contact surfaces between the insert bottom and the toolholder. www.secotools.com/mdt

Taking on titanium

With the launch of a range of Jabro highperformance tools, titanium and heat-resistant superalloys (HRSA) can now be machined with specially designed tools. JHP770 is designed for work on titanium, while JHP780 focuses on HRSAs. Both new tools offer a high metal-removal rate with security and chatter-free operation. In addition, the JHP770 model features a central channel for internal coolant, plus unequal flute spacing that prevents vibration during machining. The JHP780 features a double core design for added robustness.

The dedicated range will be available in two different geometries and two different carbide grades for a variety of specialised tasks, chiefly within aerospace applications. www.secotools.com/jabro_hpm

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in br ie f

A software revolution This spring, seco customers are seeing a completely new approach to tool software: Customer Interface (CI). This suite of Seco software applications brings the latest (and therefore most reliable) information to users of Seco products.

Thanks to new user functionalities on www.secotools.com, the CI package functions as a one-stop shop for services. The applications include a new guide for searching products, a new solution for more accurate calculations of cutting data and a new wizard to complement Seco’s threading products.

These improvements are part of Seco’s continuing effort to provide a comprehensive package of services to go with its extensive range of products. (Be sure to check for service updates at the Seco Tools website.)

A t ool for e v ery composi t e The Jabro JC800 series and Seco Feedmax™ Dura Coated Drills are new ranges of cutting tools designed to machine composite parts more efficiently. In order to meet the diverse requirements of composite materials, the series includes a wide range of specialised cutting tools. These tools eliminate fibre break-out and delamination, ensuring an improved edge finish in materials such as CFRP and CFRP sandwiched materials (Ti and Al), GRP and GRP with Al and Ti, plus a variety of honeycomb materials.

All cutters and drills feature a CVD diamond coating called Dura, a highly wear-resistant coating that makes the tools ideally suited for a task as exacting as composite-materials machining. www.secotools.com/jc800

steel away Seco expands its range of positive inserts with the C-lock chipbreaker MF2 finishing and semi-finishing insert. The new design is fully adapted to the Jetstream Tooling coolant delivery system to ensure efficient chip removal and heat control. The MF2 insert is designed with a straight edge-line that offers easy cutting of steel and stainless-steel, thanks to its positive rake angles.

The new MF2 will be launched in TP1500, TP2500, TP3500,

26 edge [1 �2011]

CP500 and TM4000 grades, together with two new Seco cermet grades: TP1020 and TP1030.

TP1020 is an uncoated cermet insert for demanding surface-finish applications with low cutting data in steel and stainless steel. TP1030 is a coated cermet with a new TiSiN-TiAlN nanolaminate PVD, offering a new level of wear resistance for higher speeds and feeds in a wider application area.

Personal assistant Every machinist could use an assistant, right? Well, thanks to Seco, you can have one at your fingertips. The Seco Tools Assistant app for iPhones is a simple program that computes the basic calculations needed on a daily basis in a machine shop. Want to know the metal removal rate in a drilling application? Easy: Just type in the values for the cutting speed, the feed rate and the depth of cut, and bingo – there it is. There are lots of other calculations available, too, and more are being added all the time. And it has one big advantage over other assistants: It’s totally free.

The magic mult ifl u t e The new Jabro-Solid2 product family for general machining applications is welcoming a new member: Jabro-Solid2 Multiflute.

Designed for all high-quality surface finishing applications, the Multiflute tool features a single geometry, and it will be available in a range of dimensions from 4mm–25mm.

Jabro-Solid2, dubbed “The Next Generation in Solid Carbide End

Mills,” is a new product range within the Jabro products collection. Seco recently introduced Jabro-Solid2 as the company’s response to the need for a universal tool capable of working in a wide range of materials – whilst offering an attractive price performance advantage – and it has been racking up impressive customer performance figures in real-life cases around the world ever since.

Get a grip The better the clamping of the tool, the higher the speed and the better the results, particularly with long machining times. A new, ready-touse device called Easyshrink® 15 achieves fast and economical shrink grip and shrink release for all shank material types. It gives operators the opportunity to experience a level of tool clamping security previously only available with the more advanced Easyshrink 20.

Easyshrink 15 supplies fast induction heating in order to expand the front of the holder, allowing the tool shank to be inserted. Easyshrink then cools the holder, which grips the tool firmly in place. Simple and effective, it provides a productivity boost and is suitable for long and short holders, plus all diameters from 3mm- to 32mm-tools.

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the perfect

joint venture

Solid carbide end mill: produces the full profile of the femoral component

Seco tools shape our equipment

and our environment, but sometimes they can also shape us. Medical technology firms order custom Seco products to create synthetic prostheses – for example, knee replacements.

8mm Wiper end mill: produces the finish on the base of the tibial tray

Condyle tool

Custom form end mill: produces ultrasmooth bearing surface

KALLISTA IMAGES

6mm