SECO NEWS SUMMARY 2016-2
NEW IMAGE NEEDED
MEET THE NEW IN-CROWD
ELITE TOOLS THAT HELP YOU STAND OUT
HIGHFEED 6
JABRO-SOLID2 JS720 AND JS730
TK1501 AND TK0501 GRADES
JABRO®-HFM JHF181
JABRO-TORNADO JH112 AND JH142
VDI BLADE ADAPTERS 150.10-JETI
JABRO-SOLID2 JS564 AND JS565
DISC MILLING CUTTERS
TGH1050 GRADE FOR MDT
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WELCOME TO SECO NEWS SUMMARY 2016-2 When you partner with Seco, you become part of a unique inner circle where everyone from tool coating specialists to applications engineers are completely focused on your success. Consider the products inside this brochure. You’ll find we’re not only developing solutions that keep pace with the natural progression of the industry, we’re also setting new standards in cutting tool development and performance. From the evolution of our Duratomic®-technology-based TK1501 and TK0501 grades for cast iron turning to the launch of our brand new JH112 and JH142 hard milling range for milling ISO-H hardened tool steels to the dramatic productivity gains provided by the new Highfeed 6, everything in Seco News Summary 2016-2 is about maximising your potential and keeping you in front of the competition.
CH PCBN GRADES
EPB 5831 SLIM HYDRAULIC CHUCKS
THREAD CHASER HOLDER
COMBIMASTER™ ER COLLET SYSTEM
PRECIMASTER™ PLUS AND NANOFIX™
COMPETENCEDRIVEN SOLUTIONS • MILLING • STATIONARY • HOLEMAKING • TOOLING SYSTEMS
Inside
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PREPARE FOR SOMETHING AMAZING
CASE STUDY: 218.21-230 VS COMPETITOR A
CASE STUDY: 218.21-230 VS COMPETITOR B
Insert: Machine: Material: Coolant: Cutting Data: DCX ZNP ap ae vc N fz vf Result: Tool Life
Insert: Machine: Material: Coolant: Cutting Data: DCX ZNP ap ae vc N fz vf Result: Tool Life Material Removal Rate
Material Removal Rate
Competitor A Burkhard + Weber MC120 34CrNiMo6 Dry Metric Inch 63 mm 2.5" 5 5 2.8 mm 0.1102" 5-25 mm 0.196"-0.984" 160 m/min 524.93 sfm 808 rev/min 808 rev/min 0.5 mm/tooth 0.019"/tooth 2,020 mm/min 79,527"/min Competitor A: 56,240 mm 2,214" 2 Parts 141.5 cm3/min 8,634 in3/min
218.21-230TR-06-M15, MS2500 Burkhard + Weber MC120 34CrNiMo6 Dry Metric Inch 63 mm 2.5" 5 5 1.8 mm 0.07086" 5-25 mm 0.196"-0.984" 178 m/min 583.99 sfm 900 rev/min 900 rev/min 2 mm/tooth 0.078"/tooth 9,000 mm/min 354.33"/min Seco: 230,880 mm 9,089" 6 Parts 404.7 cm3/min 24,696 in3/min
Productivity increased 186% and tool life increased 200%
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Competitor B Victor Power 20HP Super Duplex 32760 / MS Internal Metric Inch 52 mm 2.05" 4 4 1 mm 0.039" 39 mm 1.535" 100 m/min 328.08 sfm 625 rev/min 625 rev/min 0.45 mm 0.017"/tooth 1,102 mm/min 43,385"/min Competitor B: 6 min 6 min 42.97 cm3/min 2.622 in3/min
218.21-230TR-06-ME13, MM4500 Victor Power 20HP Super Duplex 32760 / MS Internal Metric Inch 52 mm 2.05" 5 5 1 mm 0.039" 39 mm 1.535" 80 m/min 262.46 sfm 625 rev/min 625 rev/min 0.58 mm 0.023"/tooth 1,420 mm/min 55.90"/min Seco: 13 min 13 min 55.39 cm3/min 3.38 in3/min
Productivity increased 29% and tool life increased 116%
HIGHFEED 6 Made for parts manufacturers in search of substantial productivity increases combined with exceptional tool life, our new Highfeed 6 milling cutter easily tackles a variety of difficult-to-machine materials, from stainless steel to heat-resistant superalloys, in the most effective way possible. The Highfeed 6 comprises large-diameter cutter bodies with 1,8 mm axial depths of cut and double-sided inserts with six cutting edges for unsurpassed material removal and low operating costs. The cutter performs equally well in all types of high-feed applications, including face milling and plunging operations. With the Highfeed 6, we paid close attention to the shape of the inserts and their corresponding pockets to ensure precise and stable mounting to the cutter bodies. The inserts mount at a low lead angle to direct the machining forces up into the spindle rather than radially against the side of the tool. As such, the tool experiences less vibration and can provide long, predictable performance. In comparative testing, the Highfeed 6 proved more cost effective and reliable over competitive designs, as well as led the way in productivity and tool life. In one test, the Highfeed 6 provided 186 percent more productivity and 200 percent more tool life — how’s that for amazing.
PRODUCT OVERVIEW: • • • • • •
High-performance high-feed cutter for difficult materials New double-sided inserts with six cutting edges V-shaped cutting edge ensures optimal positioning New cutter bodies with large cutting diameters Inserts mount to cutter bodies at low lead angles Effective in face milling, slotting, contouring, plunging and helical interpolation
MILLING YOUR SECO BENEFIT: • • • • • • •
Excellent cutting behaviour Highly stable performance Long, predictable tool life Increased material removal Lower cost per part Unsurpassed productivity Application versatility
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 47-49 and 61.
RANGE OVERVIEW: • • • • •
13 metric cutters with outer diameters from 50 mm to 160 mm 9 imperial cutters with outer diameters from 2" to 4" Insert comes in three cutting geometries Wide variety of advanced grade and coating options Available in normal and close-pitch cutter versions
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FEED YOUR HUNGER FOR FASTER METAL REMOVAL JABROÂŽ-HFM JHF181 High-feed milling can remove metal from a workpiece at rates that are up to 30 percent faster than traditional methods. This signiďŹ cant boost in productivity, however, can only be achieved with the right cutting tools. Meet the JHF181, the latest addition to the Jabro-HFM family of solidcarbide end mills. Because it can take small depths of cut at high table feeds, the JHF181 is an excellent choice for any high-feed milling strategy, especially when it involves machining ISO H and S materials via helical interpolation, ramping or Z-leveling.
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Our new HXT coating adds a hard top layer to the JHF181, resulting in advanced thermal protection and high wear resistance. The special edge preparation that occurs prior to coating helps reduce edge chipping. As such, JHF181 provides up to 30 percent more tool life than other comparable solid-carbide end mills when processing ISO H materials.
PRODUCT OVERVIEW: • • • • • •
Developed for high-feed milling strategies in ISO H and S materials Performs advanced machining methods such as helical interpolation Reliable end mill with extreme productivity potential Rigid tapered neck design reduces tool deflection Flute design and rear tooth angle support effective chip removal Exclusive HXT coating contributes to high wear resistance
RANGE OVERVIEW: • • • •
Available in 3-, 4- or 5-flute options Cutting diameters from 2 mm to 16 mm Length options range from 2xDCX to 7xDCX Through-tool coolant capability (6 mm to 12 mm diameters)
MILLING YOUR SECO BENEFIT: • • • • • •
Unsurpassed metal removal Superior surface finish Exceptional tool life High productivity Application versatility Through-tool coolant
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 87-89.
CASE STUDY: HARD STEEL POCKETING Application: Material: Hardness: Operation: Machine: Tool Holder: Tool: Cutting Data: N vc vf ap ae Result: Cycle Time
Typical torical shape high feed application Hardened steel 1.2379 D2 (SMG ISO-H8) 58-60 HRC Pocketing Roders RXP300 EPB 5672 high-precision collet chuck JHF181 Metric Inch 3,714 rpm 3,714 rpm 70 m/min 230 sfm 1,783 mm/min 70"/min 0.15 mm .006" 4 mm .157" Competitor: Seco: 107 min 139 min 31 components 40 components Vb 122 μm 78 μm Tool life increased 133% and workpiece quality improved
COMPETITOR 1
JABRO JHF181
VIEW OF CUTTING EDGE RELIEF AREAS
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TOOLS FOR ROUGHING UP YOUR COMPETITION JABROÂŽ-SOLID2 JS564 AND JS565 The new Jabro-Solid2 JS564 and JS565 solid-carbide end mills represent our continued focus on developing tools for advanced roughing strategies. In fact, they offer 20 percent longer tool life than their predecessors in similar situations. Featuring highly stable tapered cores, polished NXT coatings and other high-performance qualities, the JS564 and JS565 are truly the best at roughing things up. After all, they easily handle the large depths of cut, relatively small radial engagement and high speeds and feeds involved in advanced strategies. These end mills also run at an optimised arc of contact or angle of engagement, so you can easily take full advantage of the advanced roughing capabilities of a wide range of modern machine tools and aggressive CAM software tool path strategies.
Tool Life (minutes) 500 400 300 200 100 0
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Competitor
JS564
Designed for advanced roughing passes, the JS564 and JS565 can be applied at a relatively high radial engagement while maintaining the high feeds and speeds typically applied in this strategy. Furthermore, the positive frontal teeth geometries on the JS564 and JS565 make them successful in axial and helical interpolation operations. New, highly optimised chip splitter options for these end mills create small chips when using significant cutting lengths, ensuring the best possible chip evacuation. This proves especially beneficial when machining deep pockets. As a result, you can reduce operational risks, such as tool breakage and workpiece scrap. Whether your focus is on general machining operations or aerospace parts production, the JS564 and JS565 will make you a lot more efficient when it comes to rough milling ISO P, M and S workpiece materials.
PRODUCT OVERVIEW: • Solid-carbide end mills specifically developed for advanced roughing strategies • Frontal teeth geometries enable axial and helical interpolation milling • Possibility to apply high-radial engagement reduces number of sidemilling passes • Tapered core reduces tool deflection and increases dimensional stability • Finely honed cutting edges improve coating adhesion and boost tool life • Polished NXT coating reduces heat buildup for increased wear resistance • Optimised chip splitters reduce tool breakage and workpiece scrap • Tool design supports advanced CAM strategies and machine capabilities
MILLING YOUR SECO BENEFIT: • High versatility across advanced roughing applications • Stable, reliable processes • Maximum tool life • Short cycle times • High productivity • Low cost per part
RANGE OVERVIEW:
ADDITIONAL DETAILS:
• • • • • •
For further information please see catalogue / Machining Navigator Update 2016-2 pages 64-70.
New 4-flute and 5-flute designs Broad cutting diameter range Standard 2.5xDC length and long options up to 4xDC JS565 available with and without chip splitters Cylindrical shank diameters from 3 mm to 20 mm Weldon shank diameters from 6 mm to 20 mm
CASE STUDY: SIDE MILLING ROUGHING Application: Advanced roughing Material: GGG-40 (SMG ISO-K4) GGG-40 (SMG ISO-K4) Machine: Mikron HEM500U Mikron HEM500U Tool Holder: '2$ 5JTKPMƂ V Competitor Tool: JS564100D3C.0Z4C-NXT Competitor Cutting Data: Metric Inch Metric Inch N 7,960 rpm 7,960 rpm 5,730 rpm 5,730 rpm vc 250 m/min 820 sfm 180 m/min 590 sfm vf 3,185 mm/min 125"/min 2,290 mm/min 90"/min ap 15.5 mm .6" 15.5 mm .6" ae 1 mm .04" 0.8 mm .03" 0.1 mm/tooth .004"/tooth 0.1 mm/tooth .004"/tooth fz 35.5 cm³/min 2.2"3/min Q 49.4 cm³/min 3.0"3/min Result: Seco: Competitor: Tool Life 250 min 85 min Productivity 140% 100% Tool life increased 200% and productivity increased 40% compared to competitor solution
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INCREDIBLE PRODUCTIVITY IN TITANIUM-EVERY TIME
Tool Life Comparison
CASE STUDY: SIDE MILL ROUGHING Heavy side mill roughing titanium
Material: Machine:
Ti6Al4-V (SMG ISO-S12) Hermle C42 Dynamic
Tool Holder:
EPB5672 high-precision collet chuck
Tool: Cutting Data: N vc vf ap ae fz
JS720 with HXT coating Metric 2,546 rpm 80 m/min 688 mm/min 10 mm 4 mm 0.045 mm/tooth
Competitor Inch 2,546 rpm 262 sfm 27"/min .393" .157" .0018"/tooth
Tool life increased + 50% compared to competitor and machining power consumption (W) reduced 25%
Measured tool wear Vb (μm)
Application:
200
COMPETITOR 1
162
160 120 80 40 0
75.5 49
51.5 48.5
57 JS720
30 7.3
22
36
51
Tool life (min in cut) JS720 re1 = 3.0 Competitor VIEW OF CUTTING EDGE RADIUS RELIEF AREAS AFTER 36 MINUTES IN CUT.
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JABRO®-SOLID2 JS720 AND JS730 Our new 6-flute solid-carbide Jabro-Solid2 JS720 square end mill and JS730 ball nose cutter address growing industry concerns for increased reliability when performing side milling operations in titanium alloys ISO S 11, 12 and 13. Engineered to tackle these difficult materials with ease, these tools can side rough an impressive radial width (ae) of 40 percent of the cutter diameter (DC), resulting in incredibly high material removal rates. The JS720 and JS730 are also excellent choices for machining ISO M and P materials, as well as performing semi-finishing operations and advanced roughing strategies. When it comes to the advanced roughing of titanium, these end mills can run at an ae that is 7 to 15 percent of the DC. These end mills feature many notable characteristics. An irregular pitch prevents chatter. The tapered core design increases stability while allowing for a high radial width of cut. A new polished HXT coating with superior bonding ensures longer tool life. A 38-degree helix angle provides reliable cutting action in less stable conditions, while a 9-degree radial eccentric relief contributes to strong cutting edges. Additionally, the JS720 features radii optimised for aerospace structural part machining. Developed in-house, the exclusive HXT coating adds a smooth, hard top layer to the end mills, resulting in advanced thermal protection and long tool life. Furthermore, the special edge preparation that occurs prior to coating helps reduce tool chipping to increase tool life. Overall, our innovative approach to edge preparation, coating and polishing gives the JS720 and JS730 the ability to achieve up to 30 percent more tool life than similarly designed cutters. These cutters also prove to be 70 percent more productive than conventional 4-flute tools in comparable situations.
Jabro-Solid2 JS720 large RE
MILLING YOUR SECO BENEFIT: • • • • • •
Unequaled reliability Unsurpassed productivity Long, predictable tool life Excellent surface finish Short cycle times High throughput
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 71-78.
PRODUCT OVERVIEW: • • • • • • • •
Developed for side roughing operations in titanium alloys Excellent solutions for semi-finishing and advanced roughing Low helix angles provide reliable cutting action in side milling Tapered cores reduce tool deflection and increase dimensional stability Edge preparation prior to coating strengthens cutting edge stability Polished HXT coatings with superior bonding and a hard top layer Optimised chip splitters reduce tool breakage and workpiece scrap Tool design supports advanced CAM strategies and machine capabilities
RANGE OVERVIEW: • • • • • • •
New 6-flute design JS720 end mill and JS730 ball nose end mill Square end, corner radius and ball radius options Cutting diameters from 6 mm to 25 mm Corner radii on JS720 from 0.5 mm to 6 mm Cutting lengths up to 2.5xDC JS720 available with chip splitters Standard Cylindrical shanks, with Weldon and Safe-Lock™ shank options
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GET READY FOR A MAJOR PRODUCTIVITY STORM
CASE STUDY: MOULD FINISHING Application: Material: Hardness: Operation: Machine: Tool Holder: Tool: Cutting Data: N vc vf ap ae fz Result: Cycle Time
Mould W300-1.2343 (SMG ISO-H8) 56 HRC Finishing Hermle C400 EPB 5801 JH112 (6-mm cutting diameter) Metric Inch 16,000 rpm 16,000 rpm 302 m/min 990 sfm 1,400 mm/min 55"/min 0.28 mm .011" 0.2 mm .008" 0.044 mm/tooth .0017"/tooth Competitor: Seco: 290 min 464 min 5 parts 8 parts Surface quality improved and tool life increased +60%
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Tool Life (minutes) 500
SEMI-FINISHED
400 300 200 100 0
Competitor
JH112
FINISHED
JABRO®-TORNADO JH112 AND JH142
Jabro-Solid JH112
Brace yourself for the precision and productivity that comes when using our new Jabro-Tornado JH112 and JH142 solid-carbide end mills as part of a hard milling or general machining strategy. Designed primarily for semi-finishing and finishing operations in hardened steels (48 – 65 HRC), these tools easily satisfy the precision requirements of the mould, die and other industries. Featuring the far superior HXT coating, tighter tolerances (+/- 0.005 mm) and less tool run-out than their predecessors, the JH112 ball nose cutter and JH142 toroid end mill expand your machining capabilities by providing double the tool life, unsurpassed machining accuracy, higher production output and much more. Furthermore, these end mills have a broader set of options to choose from, including additional flute designs, expanded cutting diameters and corner radii sizes, different length variances and reduced shank diameters on longreach items.
PRODUCT OVERVIEW: • • • • • •
Developed for semi-finishing and finishing hardened steels Ideal for hard milling and general machining strategies JH142 can high-feed machine non-hardened materials New S-shape geometry on JH112 yields high surface finish HXT coatings with superior bonding create smooth, hard top layer Nominal cutting diameters enable easier part programming
RANGE OVERVIEW: • • • • • •
130 cutters total, with 108 metric and 22 imperial Cutting diameters from 2 mm to 12 mm and 0.063" to 0.5" Corner radii sizes on JH142 from 0.3 mm to 4 mm (+/- 0.005 mm) 2, 3 and 6 metric length variances for JH142 1, 2, 3, 4, 5 and 6 metric length variances for JH112 1 and 2 imperial length variances for both end mills
MILLING YOUR SECO BENEFIT: • • • • • • • •
Ultra-precise tolerances Optimised feed rates Excellent surface finish Superior part quality Long tool life High output Maximum productivity Significant cost-savings
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 79-86.
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MEET YOUR NEW CIRCLE OF FRIENDS DISC MILLING CUTTERS When it comes to disc milling, we’ve long offered the widest selection of inserts, cutter bodies and attachment types in the industry — and our new 335.14 and 335.16 product lines further prove it. We also go out of our way to expand our existing disc milling cutters, most recently our 335.25 line, to keep pace with the natural progression of the marketplace.
335.14 Disc Milling Cutter
335.16 Disc Milling Cutter
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Whether you perform grooving, sawing, T-slotting, copy milling, back facing or helical interpolation, you’ll find our complete selection of disc mill cutters, which now spans eight product lines, has what it takes to bring increased productivity and profitability to your parts, regardless of the industry segments you serve.
PRODUCT OVERVIEW: NEW 335.14 • Small-diameter cutters with exchangeable carbide head systems • Ideal for groove milling, circlip grooves, full radius profiles and top and bottom chamfering • Versatile, precise cutting profile easily tackles any type of material and operation • Reliable exchangeable head system controls machining costs
NEW 335.16 • Cutter features optimised for demanding T-slot operations, including specific insert staggering and design that provides room for optimal chip forming and evacuation • Inserts with four cutting edges provide economical slotting operations • Modern insert geometries reduce machining forces and noise • Nickel coating provides extended cutter body life and prevents chips from sticking to it • Centralised coolant channels assist in effective chip removal
335.25 Disc Milling Cutter
MILLING
EXPANSION 335.25
YOUR SECO BENEFIT:
• New cassettes for 16-mm and 20-mm round insert diameters • Ideal for applications involving full and half side and face milling operations with large corner radii • Exchangeable cassettes ensure long, reliable cutter performance • Inserts with at least four cutting edges help reduce the cost per part • Insert geometries provide freer cutting operations in any type of material • Design provides room for chip forming and evacuation to ensure troublefree operation and enhanced productivity
• Standard stocked disc milling solution • Trouble-free operation • High productivity • Optimised tooling costs
RANGE OVERVIEW: 335.14 • • • • •
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 12-41.
Cutter diameters from 9.7 mm to 34.7 mm (0.38" to 1.36") Cutting widths from 0.7 mm to 5.15 mm (0.027" to 0.20") Exchangeable heads with three or six teeth Wide selection of cylindrical shanks made of steel and carbide Integrated collet chuck shanks also available
335.16 • • • • •
Cutter diameters from 25 mm to 50 mm (0.97" to 1.84") Cutting widths from 11 mm to 21 mm (0.38" to 0.82") Cutter sizes based on standardised T-slot dimensions Standard stocked inserts in LNKT or SPMX Wide selection of insert geometries and grades
335.25 • • • • • • •
Cutter diameters from 100 mm to 315 mm (4" to 12") Cutting widths from 13.5 mm to 32 mm (0.53" to 1.25") Regular and extra-large cassette sizes Accepts 16-mm and 20-mm round insert diameters Wide selection of insert geometries and grades Precise, easy and reliable system to adjust cassette width Shell or arbor type connections
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CHROME COMES TO CAST IRON TK1501 AND TK0501 GRADES Our DuratomicŽ-technology-based TK1501 and TK0501 grades are once again prepared to set new standards in cast iron turning. Not only have we made these grades tougher and more wear resistant, they can help you reduce tool waste and process more parts per edge. These grades result from Seco’s EDGE INTELLIGENCE concept - an integration of our extensive high-performance insert experience and knowledge in every cutting edge to make each one count. Both TK1501 and TK0501 incorporate the latest developments in next-generation Duratomic coating technology. This gives these grades an even wider application range and an overall increase in tool life and productivity through an excellent balance of toughness and hardness for the highest performance demands.
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With our new Chrome Used-Edge Detection, both grades make it easy to tell if an insert's cutting edges have made contact with a workpiece. It is optimised to provide the highest possible contrast to make it easy to instantly identify when an edge has been used, even in low-light environments. We’ve seen situations where missed edges contribute to more than 30 percent waste inside a shop. With the TK1501 and TK0501 grades' Chrome Used-Edge Detection, you don’t need to lower your high performance demands or worry about the cost of unused insert edges.
PRODUCT OVERVIEW: • • • •
High-performance grades dedicated to cast iron turning operations Latest Duratomic coating makes grades tougher, more wear resistant New Chrome Used-Edge Detection minimises tool waste Reliable, consistent performance across a broad application range
RANGE OVERVIEW: • Comprehensive selection from roughing to finishing geometries
Revolutionary Chrome Used-Edge Detection
STATIONARY YOUR SECO BENEFIT: • • • • • • • •
Fewer unused cutting edges Long, predictable tool life Consistent part quality Good surface finish High usability Short lead times Maximum productivity Reduced waste due to prematurely discarded inserts
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 92-113.
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YOU NEED TO COOL IT VDI BLADE ADAPTERS 150.10-JETI We’ve expanded our 150.10-JETI family of parting-off blades and squareshank blocks to include a new VDI block design. This means shops with VDI turrets on their lathes can now experience the high levels of productivity and long tool life that come as a result of using these products. Together, these blades and adapters take a highly streamlined approach to delivering high-pressure coolant to the cutting zone in parting-off operations. The adapters, which hold the blades in place, install directly onto the VDI turret. Coolant is delivered internally to the adapter via the turret and then reaches the cutting zone through the coolant holes in the blades. The fast, direct transfer of coolant to the cutting edge is made possible by our advanced Jetstream ToolingŽ technology.
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PRODUCT OVERVIEW: • • • • •
New VDI adapter expands the capacity of the 150.10-JETI line Direct, high-pressure coolant delivery without any hoses Fast, efficient heat removal in parting-off operations Safe, highly effective chip control and removal Optimised positioning via edge height adjustments
RANGE OVERVIEW: • • • •
Face mount adapters for VDI30, VDI40 and VDI50 turrets Star mount adapters for VDI25, VDI30 and VDI40 turrets Holds HSS parting-off blades in 20 mm and 25 mm sizes Compatible with MDT reinforced blades with internal coolant
STATIONARY YOUR SECO BENEFIT: • • • • • • •
Optimised heat removal Effective chip control High cuttings speeds Long, predictable tool life Less spare parts (no hoses) Maximum productivity Superior part quality
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 page 122.
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GET INTO THE GROOVE TGH1050 GRADE FOR MDT The next big thing in hardened steel grooving is here — and it goes by the name TGH1050. It’s the newest member of our MDT family and the hardest, most wear-resistant carbide grade in our product portfolio. Better yet, there’s nothing else like it on the market today.
CASE STUDY: GROOVING
Operation: Grooving R2, depth 4 mm Material: 20MnCr5, Case Hardened (62-63 HRC on surface), hard and soft areas Insert: CBN Competitor Cutting Data: Metric Inch vc 160 m/min 525 sfm f 0.1 mm/rev .004"/rev Result: Tool Life 90 pcs/edge 90 pcs/edge
LCGF1604M0-0400-RP, CP200 Metric Inch 70 m/min 230 sfm 0.1 mm/rev .004"/rev
LCGF1604M0-0395-RP, TGH1050 (special) Metric Inch 130 m/min 427 sfm 0.15 mm/rev .006"/rev
70 pcs/edge
70 pcs/edge
100 pcs/edge
100 pcs/edge
Total Time/Groove (including sub-operation)
14 sec
14 sec
10 sec
10 sec
16%
14%
14%
22 sec
22 sec
Tool Cost/Groove 100% 100% 16% 2TQFWEVKXKV[ EJKR DTGCMKPI E[ENG VKOG VQQN NKHG YGCT RTGFKEVCDKNKV[ CPF VQQN EQUV KORTQXGF UKIPKÆ‚ ECPVN[
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Featuring an ultra-fine grain substrate with very high hardness and a tough nanolaminate PVD coating, this advanced carbide grade is substantially harder than traditional tungsten carbide solutions and can deliver performances that are on par with PCBN inserts. When processing hardened materials, TGH1050 provides the best of both worlds. Its performance approaches PCBN levels, while still offering the benefits of carbide grades. At the same time, the levels of performance and tool life with TGH1050 exceed what can be reached with conventional carbide grades. Manufacturers, especially those in the automotive sector, that run grooving operations on case hardened steels will greatly benefit from TGH1050. Whether it involves the hard top layer or the softer middle section of a part, the grade remains highly effective throughout the entire process. TGH1050 comes in two insert geometry shapes with excellent chip forming properties. The square FT geometry performs best in grooving and fine turning applications, while the round-shaped MP geometry excels in profiling operations.
PRODUCT OVERVIEW: • • • • • •
Top choice for grooving in hardened steels Good option for superalloy materials Very hard and wear-resistant ultra-fine substrate Tough nanolaminate PVD coating Strong complement to PCBN grades Better performer than conventional carbide grades
RANGE OVERVIEW: • Available in widths from 3 mm to 6 mm • Comes in FT (square) and MP (round) insert geometries
STATIONARY YOUR SECO BENEFIT: • • • • • •
High wear resistance Fast cutting speeds Unsurpassed performance Maximum productivity Application versatility Great chip-breaking capability • Substantial tool savings • Longer tool life than conventional grades • Less tooling inventory
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 119-121.
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SCHOOL THE COMPETITION IN HARD KNOCKS CH PCBN GRADES Our latest PCBN grades are as tough and wear-resistant as they come. Thanks to a new bimodal substrate with coarser grain materials, these hard part turning solutions easily bring exceptional tool life and superior surface finish to hardened steel parts production. With the addition of 11 new insert geometries to our PCBN grades, these benefits can be achieved in an even wider variety of applications. The grades in our PCBN range — CH0550, CBN060K, CH2540 and CH3515 — cover the entire hard part turning spectrum, from continuous cuts to heavy interruptions. In other words, they can easily handle any ISO H05 to H35 material challenge that stands in your way, with the end result being part quality that is second to none.
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While each grade serves a unique purpose, they all feature advanced characteristics that allow them to maintain the longest possible tool life at high cutting speeds. Test results show that in extreme applications, these grades can deliver up to three times longer tool life than competitive products.
PRODUCT OVERVIEW: • • • • •
11 new geometry introductions in PCBN grades Developed for hard part turning in hardened steels New substrate and coating process optimises grade performance CH0550 provides high-speed continuous cuts in H05 materials CBN060K excels in continuous or medium-interrupted cuts in H15 materials • CH2540 accommodates light-to-heavy interruptions in H25 materials • CH3515 takes on heavy interruptions in H35 materials
RANGE OVERVIEW: • Four grades fulfill every hard part turning requirement • Available in common ISO insert geometries (metric and imperial) • Wiper geometry options
STATIONARY YOUR SECO BENEFIT: • • • • •
Application versatility Unsurpassed tool life Superior surface quality High process stability Maximum productivity
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 114-118.
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SITS TIGHT IN TOUGH SITUATIONS THREAD CHASER HOLDER Previously only available in a square shank design, our thread chaser holder now supports shops using Steadyline™ vibration damping bars or Capto® tooling to produce API and common licensed thread profiles in hard, gummy and high-chrome materials. Adapted for tooling with Capto C6, Capto C8 or Steadyline GL50 connections, these new holders accommodate a wide selection of multitooth thread chaser inserts that efficiently perform external push and internal push or pull threading operations. The special carbide-pin locating systems, patented pocket seat surface patterns and high-pressure coolant delivery on these holders ensure accurate insert positioning, superior rigidity and effective chip evacuation.
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The holders also rely on top and axial clamping forces to maintain a tight insert grip during the threading process, resulting in long, predictable insert life and lower tooling costs. Together, these inserts and holders reduce the number of passes it takes to produce consistent, high-precision full thread profiles.
PRODUCT OVERVIEW: • • • •
Developed for use with Capto and Seco Steadyline tooling Two-pin system ensures precise positioning from insert to insert Scalloped pocket seat pattern increases insert support Optimal chip formation through direct coolant delivery of up to 200 bar with square shank holders • Steadyline and Capto versions provide direct coolant delivery to maximum 70 bar
RANGE OVERVIEW: • Capto design supports C6 and C8 connection sizes • Steadyline design supports turning heads with GL50 connection • Multi-tooth inserts come in push or pull and push/pull sets
STATIONARY YOUR SECO BENEFIT: • • • • • •
Application versatility Rigid, reliable performance Consistent, accurate results Long, predictable tool life High productivity Increased profitability
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 123-127.
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HARD CHOICES LIE AHEAD NEW HIGH-PERFORMANCE GRADES FOR PRECIMASTER™ PLUS & NANOFIX™ Typically, no one enjoys making hard choices. When it comes to our Precimaster Plus and Nanofix reaming systems, however, you’re going to like the hard choices we’re putting in front of you. Meet the new RN2010, RM2090 and RS2090 grade options for the Precimaster Plus modular system's solid-carbide interchangeable heads and the Nanofix range of solid-carbide reamers.
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Featuring high Vickers hardness, these grades bring tight tolerances, high process security and exceptional tool life to demanding blind and through-hole reaming operations in ISO N, M and S materials. They undergo special edge preparation and have specific cutting geometries that make them highly optimised for processing these materials. No matter the grade, each reamer head has an impressive number of cutting teeth per diameter, allowing them to run at feed rates that are 30 percent faster than competitive designs. Surface finishes between Ra .4 and Ra .8 are also easily achievable. Furthermore, the patented connection of the Precimaster Plus provides fast head exchanges with a repositioning repeatability and run-out of under three microns. New grades for M, N and S material are offered for Nanofix solid carbide reamers ranging from 3 mm to 12 mm (.117" to .474").
PRODUCT OVERVIEW: PRECIMASTER PLUS • • • •
Disposable, indexable heads optimised for specific applications RN2010 uncoated sub-micrograin grade for ISO N materials RM2090 coated wear-resistant grade for ISO M materials RS2090 coated wear-resistant grade for ISO S materials
NANOFIX • • • •
Solid carbide reamers for specific applications RN2010 uncoated sub-micrograin grade for ISO N materials RM2090 coated wear-resistant grade for ISO M materials RS2090 coated wear-resistant grade for ISO S materials
RANGE OVERVIEW: PRECIMASTER PLUS • • • • • •
HOLEMAKING YOUR SECO BENEFIT: • • • • • • • •
IT7 hole tolerances High process security Consistent performance Long, predictable tool life Superior surface finish Fast, easy tool setup Short cycle times Low cost per part
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 128-133 (Nanofix) and 134-139 (Precimaster Plus).
New grades join five existing coated and uncoated grades Cutting diameters from 10 mm to 60 mm (.394" to 2.362") Universal, aggressive feed and fine finish lead geometries Floating and adjustable shanks in four standard diameter sizes Short, medium and long length shank options Tool body coolant outlets available for through and blind-bore applications
NANOFIX • • • • •
New grades join three existing coated and uncoated grades Cutting diameters from 2.97 mm to 12.050 mm (.117" to .474") Universal, aggressive feed and fine finish lead geometries Common shanks for through and blind holes Accurate connection
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YOUR NEW SLIM DOWN STRATEGY EPB 5831 SLIM HYDRAULIC CHUCKS We’ve expanded our line of hydraulic chucks by taking a slimmed down approach. Our latest EPB 5831 has a slender profile that makes it easy to perform semi-finishing and finishing operations in confined spaces such as narrow mould cavities. The EPB 5831 uses high pressure and a single pressurised screw to uniformly grip small-diameter cutting tools with excellent precision and repeatability. Reduction sleeves allow the chuck to hold various shank types and diameters, while a stop end screw makes it easy to set the projection of your tool.
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PRODUCT OVERVIEW: • • • • • • •
Slender profile supports interference-free machining Long projections reach deep into workpiece cavities High-precision run-out accuracy less than 5μm at 3xØ Ideal for semi-finishing and finishing operations Fine balanced for high rpm Rotational speeds up to 40,000 rpm Safe, repeatable clamping without the use of specific device
RANGE OVERVIEW: • Accommodates 6-mm, 8-mm, 10-mm and 12-mm tool diameters • HSK-A63, HSK-A100, BT40 and Seco-Capto™ C5 machine side connections • Available in projection lengths of 150 mm or 200 mm • Reduction sleeves for tool diameters 3 mm, 4 mm, 5 mm, 6 mm, 8 mm and 10 mm for hydraulic chuck 12 mm
TOOLING SYSTEMS YOUR SECO BENEFIT: • • • • • • •
Ease of use Repeatable clamping High run-out accuracy Smooth, stable cutting Excellent surface finish Long tool life Operator safety
ADDITIONAL DETAILS: For further information please see catalogue / Machining Navigator Update 2016-2 pages 140-145.
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THE TOOLING SYSTEM YOUR MULTI-TASK MACHINE DESERVES COMBIMASTER™ ER COLLET SYSTEM Multi-task machines offer a great deal of manufacturing flexibility. But they can’t do it alone, as they require cutting tools that are just as versatile as they are. Meet our new Combimaster ER collet system that brings ease of use, stability and unlimited possibilities to these machines. Compact and highly adaptable, this tooling system performs face, side and disc milling operations via insert-based milling cutters, as opposed to solid end mills. This achieves higher material removal rates due to larger cutting diameter capacities. For example, ER25 standard collets are limited to solid end mill shanks of 16 mm in diameter, compared to Combimaster size M12 Turbo milling heads of up to 25 mm in cutting diameter.
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Unlike anything else on the market, the system combines ER collets, ER clamping nuts and a ball bearing interface that allows for unmatched tool positioning and tightening during setup. Available in three ER sizes and five different Combimaster thread-size connections, the system supports a wide range of interchangeable milling cutter heads, especially those in the Turbo line.
PRODUCT OVERVIEW: • Compact design with short overhang saves space in machining area • Ball bearing clamping nut interface allows for better tool positioning and fast setup • Provides productive face, side and disc milling operations on multi-task machines • Combimaster cutters offer larger cutting diameters than solid end mills • Robust thread connections provide maximum holding strength
RANGE OVERVIEW: • • • •
ER25 collet with Combimaster size M8, M10 & M12 connections ER32 collet with Combimaster size M10, M12 & M16 connections ER40 collet with Combimaster size M12, M16 & M20 connections Full selection of Combimaster milling cutter heads, including internal coolant designs
TOOLING SYSTEMS YOUR SECO BENEFIT: • Increased cutter diameters for higher material removal rates • Reduced tooling costs and faster setup than systems using solid end mills • Unmatched stability • Exceptional repeatability • Long tool life • Ease of use • Application versatility
ADDITIONAL DETAILS: For further information please see the catalogue / Machining Navigator Update 2016-2 pages 146-147.
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