custom tooling - winning solutions epb

Custom toolingWinning solutions EPB

vErsion 2013-1

HQ_BRO_EPB_Custom_Tooling_CS6.indd 1 7/4/2013 1:57:13 PM

2


Seco works closely with manufacturers to create and provide solutions that increase productivity and bolster profitability. With 5,000 team members in over 45 countries, we offer a globally networked resource dedicated to solving your challenges and supporting your operations. Through cooper-ative partnerships with manufacturers and entities around the world, we monitor trends, identify challenges and develop solutions that overcome the industry’s most demanding applications.

When you work with Seco, you experience a true partnership based on trust, respect and communication. Our solutions exceed milling, holemaking, turning and tool holding products, as we work closely with your team to address and improve every aspect of production. For over 80 years, Seco has developed the tools, processes and services that leading manufacturers turn to for maximum performance. Whatever challenges you encounter, our team is always nearby to help you overcome them through extensive expertise and high quality products.

Seco customers can also access the latest information regarding new pro-ducts, machining data, manufacturing techniques and other developments by visiting our website at www.secotools.com.

EnhanCing your ComPEtitivEnEss

Seco-EPB technologies........... 4

Seco-EPB Custom Tooling ..... 5

Wind Power Case 1: Wind turbine casing fine boring ø 3200 mm ............ 8 Case 2: Stator frame fine boring ø 2717 mm .......... .8 Case 3: Wind turbine casing fine boring ø 2700 mm .......... ..9 Case 4: Transmission shaft fine boring .............................. ..9

Agriculture Case 5: Casing multistep rough boring .......................... 11 Case 6: Combined boring bars for tractor engine ................... 11

Case 17: Multistep fine boring in casing (2) ...................................20

Case 18: Square shoulder milling ...20 Case 19: Examples of fine boring bars with Steadyline™ ..............21 Case 20: Deep internal boring with Steadyline™ ......................21 Case 21: Examples of multi-cut fine boring bars ........................22 Case 22: Examples of milling holders with Steadyline™ ........22

Automotive

Case 13: Cam and crankshaft line boring ............................. 17 Case 14: Cylinder housing, cam and crankshaft fine boring .... 17

General Engineering & Others

Case 15: Long overhang rough boring ........................... 19 Case 16: Multistep fine boring in casing (1) .................................. 19

Oil & Gas

Case 7: Valve fine boring ....... 13 Case 8: Hydraulic jack boring ... 13 Case 9: Three way valve back boring ............................ 14 Case 10: Screw pump fine boring ..................................... 14 Case 11: Milling main block .... 15 Case 12: Water pump housing fine boring 2 ............ 15

3


sECo-EPB tEChnologiEs

stEadylinEtm viBration damPing systEm A built-in vibration absorber dampens the vibration as soon as it is transmitted by the cutting tool to the body of the holder; it prevents it from spreading along the bar, thus limiting the deflection of the assembly.Much higher cutting conditions, with quieter operation and optimium stability can be achieved, increasing productivity and surface finish, as well as the tool and the spindle life-time.In parallel to our standard range, the Steadyline™ technology is integrated in many Custom Tooling applications.

jumBo BridgE Bars For very large diameter boring, our range of Jumbo bridge bars provide unequaled results. Jumbo bridge bars exist as standard from ø654 to 2155 mm but we have designed and implemented, with success, bridges over 3 metres wide, with or without guides.Jumbo bridge bars made of high tensile aluminium with steel interface, are designed to hold two Bridge bars in several positions. Fitted onto a face milling cutter holder ø60 mm, or fitted directly onto the machine spindle (DIN2079/50 front end), or using the centering spigot.

miCromEtriC adjustmEnt Seco-EPB preferably uses the standard micrometric adjustment screws in all Custom Tooling applications. The setting mechanism ensures an adjustment down to 2,5 µm on diameter through a vernier scale.The precision of the mechanism guarantees repeatable accuracy.

antifriCtion rotary Bushings Used to support and guide the cutting tool, the rotary bushings consist of a stationary outer case and an inner liner, set on antifriction lubricated precision bearings, that rotate with the cutting tool.Bearings can handle any radial or axial load and provide the rigidity required to produce precision cuts.

Advantages: •Built-inprecisiontoborequality6 •Frictionfreerotation •Consistentpartquality •Improvedprocesscapability

4


sECo-EPB Custom tooling suPPort Our pricing department can offer a quick response to pricing requests, through our worldwide sales network. Complicated offers are submitted with easy to read 3D-CAD drawings.

Our application engineers, with their strong technical background, will support you from enquiry to installation and implementation directly at your facilities. Our target is to provide you with a winning solution in the shortest possible time.

Custom tooling WorkshoP Seco-EPB’s Custom Tooling workshop is a separate entity within the main manufacturing plant; completely independent from standard ‘catalogue’ product manufacturing. Thanks to a complete range of modern mill-turn machines, precise grinding centres, and 3D control devices, we ensure a high level of quality and precision.

sECo-EPB Custom tooling

Example of 3d drawing supplied with CT-Offers.

5


Wind PoWEr

6


7


CasE 1: Wind turBinE Casing finE Boring

CasE 2: stator framE finE Boring

Material: GGG40

Machine: FPT, M+ARX, SA50

Operation: Boring: ø 3200 0/-0,3, 250 mm deep Boring: ø 3280H7, 10 mm deep Back boring: ø 3220H7, 15 mm deep

Tool: Jumbo bridge bar in high tensile aluminium, 300 kg, length 2810 mm.

Insert: TCMT110208F1-HX

Cutting vc fz nconditions: Metric 220 m/min 0.15 mm/rev 22 rev/min

(Ø 3200x250) Inch 722 sf/min 0.006"/rev 22 rev/minvf ap

Metric 3.3 mm/min 0.5 mmInch 0.129"/min 0.02"

results • Machining time: 75 min • Rz: 16• Diameter deviation: 0.02 mm on diameter after 17km tool engagement

Material: Steel SMG3

Machine: PAMA Speedram 4000, SA60

Operation: Boring ø 25270/-0,25, 30 mm deep Boring ø 27170/-0,25, 90 mm deep


Insert: CCMT09T308-F1, TP1500


Inch 656 sf/min 0.006"/rev 24 rev/minvf ap

Metric 3.6 mm/min 0.5 mmInch 0.14"/min 0.02"

results • Machining time: 25 min• Roundness: 0.02 mm

8


CasE 3: Wind turBinE Casing finE Boring

CasE 4: transmission shaft finE BoringMaterial: Case hardened steel (58HRc)

Machine: Millturn Mori Seiki- HSK-A100

Operation: Boring internal profile ø 280H7, ø 319H7 Grooving and threading

Tool: Boring bar with integrated Steadyline vibration damper, L=800 (9xD), 43 kg. Roughing and fine boring with the same cutting head with 2 different inserts at 180°.

Insert: CCMT09T304-F1, TH1500 & TH1000

Cutting vc ap fz

conditions: Metric R: 80 m/min R: 2 mm 0.15 mm/revF: 150 m/min F: 0.3 mm

Inch R: 262 sf/minF: 492 sf/min

R: 0.079"F: 0.012"

0.006"/rev

results • Improved surface finish • Higher productivity• Increased insert life time

Material: GGG40

Machine: Horimaster 5, Schiess, SA60, 3 metre RAM at ø 560

Operation: Boring: ø 2690H7, 300 mm deep Boring: ø 2700H7, 65 mm deep


Insert: CCMT09T308-F1, TK2000



Metric 3.0 mm/min 1 - 1.25 mmInch 1/2 finishing

0.118"/min0.039 - 0.049"

Insert: CCMT09T308F1-TK2000



Metric 3.0 mm/min 0.5 mmInch Fine boring

0.118"/min0.02"

results • Machining time: 100 min • Rz: 10• Diameter deviation: 0.03 mm on diameter after 17 km tool engagement

9


agriCulturE

10


CasE 6: EXamPlEs of Boring Bars Com-BinEd With stEadylinE™ viBration damPing systEm for traCtor EnginE ComPonEnts

CasE 5: Casing multistEP rough BoringMaterial: Cast iron

Machine: MCM

Operation: Multistep rough boring, ø 75, ø 87,5, ø 109 Chamfering 30° in one step

Tool: Boring bar (4 cartridges) with antifriction rotary bushing with radial compensation.

Insert: CCMT09T308-F1, TK2000

CCMT120408-F2, TK2000

CCMT160508-F2, TK2000

Cutting vc fz ap

conditions: Metric 120 m/min 0.25 mm/rev 37 mm/diameterInch 394 sf/min 0.01"/rev 1.45"/diameter

results • Machining time: 30 sec. Previously made by interpolation milling: 10 min

11


oil & gas

12


CasE 8: hydrauliC jaCk BoringOperation: Boring ø 210-350, depth up to 8000 mm

Tool: 3 cartridge boring head with antifriction rotary bushing with radial compensation.

results • Improvement in productivity

CasE 7: valvE finE BoringOperation: Long overhang fine boring with interrupted cut

Tool: Boring bar D=75xL=700 (9xD) with integrated damper.

Insert: CCMT09T304-F1, CP500

Cutting vc fz

conditions: Metric 150 m/min 0.10 mm/revInch 492 sf/min 0.004"/rev

results • Improvement in insert life time, productivity and surface finish

13


CasE 9: 3 Way valvE BaCk BoringMaterial: Forged Duplex stainless steel SMG10

Operation: Back boring ø 96, ø 142, ø 169 and ø 202

Tool: Boring bar with integrated damper, interchangeable cutting heads, perfomed with Jetstream Tooling®.

Insert: Roughing: CNMG120408-M5, TP3500 Finishing: DNMG150608-MF1, TS2000

Cutting vc ap

conditions: Metric 40-80 m/min R: 2 mm F: 0.012 mmInch 131-262 sf/min R: 0.079" F: 0.012"

fz

Metric 0.25 mm/revInch 0.01"/rev

results • Improvement in productivity, insert life time, and surface finish

CasE 10: sCrEW PumP housing finE BoringOperation: Fine boring with interrupted cut

Tool: Carbide fine boring bar with integrated vibration damper, up to 12xD fitted in OZ collet chuck.

Insert: CCMT09T304-F1, CP500

Cutting vc fz

conditions: Metric 150 m/min 0.10 mm/revInch 492 sf/min 0.004"/rev

results • Improvement in productivity, insert life time, and surface finish• Consistency in centre distance of the bores• Consistency in size of main and idler bores

14


CasE 11: milling main BloCkMaterial: Steel SMG4

Machine: Juaristi, SA50

Operation: Helical interpolation milling ø162x442

Tool: E3471555532520, SA50 Steadyline™ d=32 x A=520 with high feed cutter R220.21-0088-160-5C, ø 88 x GPL550

Insert: 218.19-160T-04-M08, F40M

Cutting vc fz vfconditions: Metric 144 m/min 0.96 mm/tooth 2500 mm/min

(Ø 3200x250) Inch 472 sf/min 0.038"/rev 98"/minn ap

Metric 520 rpm 1 mmInch 520 rpm 0.039"

results • 42 minutes, 64% better than with previous solution• Better surface finish

CasE 12: WatEr PumP housing finE Boring Operation: Blind, multistep fine boring

Tool: Boring bar with lubricated guiding bushes, alu bridges with 3 adjustable fine boring heads.


15


automotivE

16


CasE 13: Cam and Crankshaft linE BoringOperation: Fine boring ø 58H7 and ø 87H6 in one step

Tool: Adjustable fine boring head (type Libraflex® or Liteline®) performed with antifriction rotary bushing.

results • Achieving concentricity within 20 microns

CasE 14: CylindEr housing, Cam and Crankshaft finE BoringOperation: Semi-finishing and fine boring, line boring

Tool: • Boring bar for semi-finishing and finishing cylinder housing in one step with 3 PCBN inserts (1 wiper for finishing). • Steadyline™ fine boring bars with micrometric adjustment for cam and crankshaft line boring.


17


gEnEral EnginEEring & othErs

18


CasE 15: long ovErhang rough BoringMaterial: Steel SMG3

Machine: TOS Kurim FUQ 150

Operation: Rough boring 10xD, ø 39-51 mm

Tool: Rough boring bar with integrated damper Seco-Capto™ C8, GPL=575 mm.

Cutting vc vf nconditions: Metric 138 m/min 230 mm/min 1100 rev/min

(Ø 40 mm) Inch 453 sf/min 9"/min 1100 rev/minf ap

Metric 0.008 mm/rev 2.5 mmInch 0.008"/rev 0.1"

Cutting vc vf nconditions: Metric 165 m/min 184 mm/min 1050 rev/min

(Ø 50 mm) Inch 541 sf/min 7.2"/min 1050 rev/minf ap

Metric 0.007 mm/rev 2.5 mmInch 0.007"/rev 0.1"

Insert: CCMT09T304-F2, TP3500

results • Longer insert life• improved productivity

CasE 16: multistEP finE Boring in Casing (1)Operation: Fine boring ø 120 H7 (2x), ø 110H7, and ø 145H7

Tool: Fine boring head with 4 micro-units, with integrated damper, A=615.

results • The 4 bores are machined with a run-out under 20 microns

19


CasE 17: multistEP finE Boring in Casing (2)Operation: Multistep fine boring

Tool: Multistep fine boring bars with aluminium bridge bars to achieve hole diameter quality IT6.


CasE 18: squarE shouldEr millingMaterial: S355 (SMG3)

Operation: Square shoulder milling

Machine: WHN 130, SA50

Tool: Steadyline face mill holder with R220.96-0080-08-7A, tool length 370 + spindle=560

Insert: XNEX080608TR-M13

Cutting Dc zn vc

conditions: Metric 80 mm 7 260 m/minInch 3.15" 7 853 sf/min

vf fz ap

Metric 1540 mm/min 0.2 mm/tooth 1 mmInch 60"/min 0.008 ipr 0.04"

n ae

Metric 1100 rev/min 80 mmInch 1100 rev/min 3.15"

results • Double depth of cut• Approximately 60% faster than previous solution

20


CasE 19: EXamPlEs of finE Boring With stEadylinEtm

Operation: Fine boring up to 10xD

Tool: Fine boring with integrated vibration damper to increase stiffness. Bodies made of steel or aluminium when overall weight reduction is needed, for larger boring bar.

results • Improvement in productivity, insert life time and surface finish

CasE 20: dEEP intErnal Boring With stEadylinEtm

Material: SMG 5 and 10

Operation: Fine boring (ø 230H7)

Tool: Boring bar with integrated damper, in aluminium with short and light head L=750 mm, 24 kg.

Insert: DCMT11T304-F1, TP3500

Cutting vc fz ap

conditions: Metric 240 m/min 0.2 mm/rev 2 mmInch 787 sf/min 0.008"/rev 0.079"

results • Surface finish• Productivity• Insert life time

21


CasE 22: EXamPlEs of multi-Cut finE Boring BarsOperation: Fine boring | Back boring

Tool: Multi-step fine boring bars made of steel or aluminium, with micrometric units achieving hole quality IT6.


CasE 23: EXamPlEs of milling holdErsWith stEadylinEtm

Operation: Long overhangs on large, complex monolithic work pieces, deep cavities and difficult to access machining areas.

Tool: Long milling assemblies (up to 10xD) with integrated damper to improve dynamic stiffness, insert life time, surface finish, and overall stiffness.


Multicut milling holders Machining time: 10s. vs. previously 60s.

Shrinkfit

Combimaster

Shell mill holders

22


23


sECo tools aBsE-737 82 fagErsta, sWEdEntEl. +46 223 400 00WWW.sECotools.Com

02863416, ST20136419 GB, © SECO TOOLS AB,2013. All rights reserved. Technical specificationsare subject to change without notice.


custom tooling - winning solutions epb

Documents