the minimaster storyrevolution

“It was a new and complicated design”

special tools for the

a380 airliner

perfect labelsthanks to perfect holes

a magazine from seco #1.2011

since its introduction almost three decades ago, Minimaster® has been used by scania to produce components for diesel trucks.

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 60Internet 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

30/50%

x2–42–4 times higher produc-tivity than with conventional shell mill holders

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.

g o o d v i b e sThE STEAdylInE shell mill holder increases machining quality and lowers costs in milling operations. Its vi-bration absorber dampens vibration and thus improves the dynamic stiffness of the shell mill holder, preventing it from chattering. Steadyline increases productivity, impro-ves surface finish and extends tool life.

www.SECoToolS.CoM/STEAdylInE Product availability: noworder & application data: Machining navigator 2011

#2 how it work s s t e a d y l i n e ™

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

Central coolant tube to feed coolant to the cut-ting edge

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

APPlICATIon: MdT Multidirectional turning technology is helping Mae in new Zealand create moderators for firearms.14

InduSTry: FIllIng And PACkAgIng Krones has been making labelling machines since 1951. today, production takes advantage of Xfix™.04

ProFIlE: TrACIE ClArkE seco’s Manager of strategic programs in north america shares her story.18

MATErIAlS: CArBon CoMPoSITES Aviation supplier Aircelle works with Seco to develop customised solutions to specific tasks.10

ProduCTS: MInIMASTErthe Minimaster revolutionised end milling in 1983, and the Minimaster plus aims for the same.21

ProduCTS: PowEr 4™the power generation industry gets higher per-formance with the power 4 copy milling cutter.08

on ThE joB: MIChAEl rIChArdSonadvanced cutting tools ltd’s managing director tells about seco’s productivity & cost analysis (pca).24

In your hAndS you hold the first Edge of 2011, an appealing introduction to Seco’s latest high-per-formance 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 first-class 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 exam-ple, 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 maga-zine continues to be an enjoyable part of your day.

paul löfgren senior vice president, group marketing edge@secotools.com

10every job

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

c o n t e n t s e d i t o r i a l #1.2011

03edge [1 �2011]

XfixSeco’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

hole hearted

04 edge [1 �2011]

i n d U s t r y F i l l i n g a n d P a c K i n g

hole hearted

Labelling machines re-quire perfect holes in

order to work prop-erly. Xfix reamers

are helping improve accuracy at the production line at Krones.

TexT Michael lawton PhoTo Martin hangen

IF 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 bot-

tles, cans and other contain-ers every day.

Over the years, Krones has developed into virtually a one-

stop shop for the drinks indus-try—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.

05edge [1 �2011]

The main factory in Neutraubling, in northern Bavaria, makes machines

for filling, labelling, inspection, trans-port 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 particu-larly important for a manufacturer, because labels show how a brand positions itself in the market – so they have to be good.”

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.

Component: Mould plateoperation description: reamingMachining objective: correct hole quality (H6 and m6 tolerance)

& reduction in machining timeMachine tool: machining centreTool clamping: HsK-a arborsMaterial: 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/revresult: Tool life > 200 minutes

wolfgang gottschalk heads up one of krones’ five produc-

tion units in nittenau, germany.

06 edge [1 �2011]

longer tool life

i n d U s t r y F i l l i n g a n d P a c K i n g

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 proc-esses.” 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 Hu-ber 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.”

07edge [1 �2011]

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Power 4 allTexT 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 Ap-plication 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, simpli-fying set-up for the operator.

The patented pocket seat has a maximised contact area between the insert and the body, adding reliability and sta-bility. To maintain the tight tolerance needed for high-qual-ity 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.

P r o d U C t s P o w e r 4

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.”

1

3

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.”

USD trend“The global econ-omy 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 imbal-ance and lowering the risk of new financial crises.”

TexT ylva Carlsson i llusTraTion johan nohr

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.

o u t l o o K gl ob a l t re nds

2Supply 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. Produc-tion disruptions such as crop failure could generate temporary price increases for agricultural products.”

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 consump-tion in the coming years.”

trendsthat impact raw material prices

4

09edge [1 �2011]

10 edge [1 �2011]

abovea CUtAircelle 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

m at e r i a l s c a r b o n c o m P o s i t e s

11edge [1 �2011]

ph

oto

: isto

ck

ph

oto

ow A SuBSIdIAry of French defense and aerospace conglomerate SAFRAN, Aircelle

was founded in 1896 to produce armaments in the Norman-dy port of Le Havre. Since then it has grown to be a leading player in the global market for nacelles (covering compo-nents 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 bounda-ries, 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 composite-carbon 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 chal-lenged all our tool suppliers with samples of the composite material,” says Boulet.

The workpieces are made up of two materials: a 12mm-thick carbon-fibre composite and a 40mm-thick carbon hon-eycomb 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, Computer-Assisted Manufacturing (CAM) and Automation Manager. “Moreover, this faster cutting solution had to maintain the

NThe high-tech materials that Aircelle uses are notoriously

difficult to machine.

Cut into the matrixnew 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 pre-cise milling needs, providing an extended tool life with higher speeds and greater cutting precision. These solid carbide end mills have a CVD dia-mond 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 compos-ites, high performance engineering plastics and honeycomb materials.

www.SECoToolS.CoM/jCProduct availability: noworder & application data: Tools for advanced and modern materials. The Solid End Mill catalogue will be available March/April.

edge [1 �2011]12

We wanted to find a solution that could cut

through in a single pass with a single tool.

Seco worked with Aircelle to develop

customised tools for specific tasks.

Component: Aircraft engine coversoperation description: slot millingMachining objective: machining distance 4000 mm, no

burring on componentMachine tool: machining centreTool clamping: High precision shrinkfit holderMaterial: carbon fibre or carbon fibre-

aluminium compositeCutter/Tool: Jc860 Honeycomb router cutter,

diameter 10mm, Dura coatingCutting data: vc: >150 m/min

vf: 300 mm/minap: > 35 mmae: 10

Coolant: Dry machining recommended

Component: Aircraft engine coversoperation description: routingMachining objective: machining distance 16000 mm, no

burring on componentMachine tool: machining centreTool clamping: High precision shrinkfit holderMaterial: carbon fibre compositesCutter/Tool: Jc871 Honeycomb router cutter,

diameter 10mm, Dura coatingCutting data: vc: >300 m/min

vf: 1500 mm/minap: > 10 mmae: 10

Coolant: Dry machining recommended

integrity of the composite and provide us with a high-quality 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 tailor-made 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 Air-celle’s production in the near future.”

no burringon component

edge [1 �2011] 13

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 im-pact. 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 Gun-nar 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 sustain-able development, we are making a positive contri-bution to the local community,” Lobell says.

Seco has overall environmental targets aimed at reducing the environmental impact from waste, chemical products, energy consumption and trans-port. The tool being used to achieve this is a com-mon 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 environ-mental studies, training of employees and clear rou-tines. 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.

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 sub-

stances 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.

sustainable goals

s U s t a i n a b i l i t y

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

Seco stepped up the company’s recycling pro-gramme in 2010; customers in all markets can now sell back used inserts and solid cemented carbide tools. The long-term targets are ambitious; for exam-ple, by 2014 the goal is to recycle 50 percent of all the carbide products Seco delivers.

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a P P l i C at i o n m d t

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Sk MAE FoundEr Gary McColl what his New Zealand-based com-pany 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 con-tinue to hear what’s happening around them as they fire – a significant safety improvement in a dangerous job.

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

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 – some-times sending it running straight towards the hunter.

MAE customers have reported other unexpect-ed 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

A We can program a job with confidence, knowing it will complete the run without any issues.”gary McColl, founder, MAE

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

oUt of earshotTexT diana Clement PhoTos derek Cook and Image Source

15

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 Mc-Coll, 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 rigid-ity 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™.

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

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, flexibil-ity and hole quality. www.secotools.com/crownloc

Quattromill For high-performance face milling in virtually all types of materials and machine tool sizes, Quat-tromill 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 com-ponent stability.www.secotools.com/quattromill

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

Sales manager Stu Beresford demon-strates a newly manu-factured moderator. MAE’s moderators reduce the noise from gunshots, sparing the hearing of hunt-ers, police and army personnel.

a P P l i C at i o n m d t

edge [1 �2011]16 edge [1 �2011]

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A CuTTIng EdgE has a hard life. With today’s workpiece materials and cutting conditions, it’s heavily attacked from all sides – mechani-cal loads! Chemical attacks! Ther-modynamic assaults! Modern cut-ting 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 sud-denly – 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 funda-mental to controlling the cutting

the edge whisperer

four signs a cutting edge is about to break:

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.

process for high-quality workpiec-es. 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 produc-tivity, 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 hap-pen: Can you see the “grey zone” on the cutting edge, for example? The very subtle chipping and crum-bling? 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 sec-onds 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 repre-sentative 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

Cutting powerBurringChip shapeChip colour

17

i n s i g h t m a C h i n i n g a b i l i t y

P o r t r a i t t r a c i e c l a r K e

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TexT linas Alsenas PhoTo Eric P. Mull

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 Worcester-shire County, Clarke began a four-year techni-cal 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.”

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

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 personal-ity 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.

Making

T“ I’ve

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

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Name: Tracie ClarkeAge: 38Background: After completing her apprenticeship, Clarke worked full-time as a CNC operator for four years at Rolls-Royce (which had acquired Northern Engineer-ing 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 train-ing course. Clarke moved to Detroit in 2010 for her current position as Manager of Strate-gic Programs.Outside interests: Clarke is an accomplished scuba diver, having been certified as a res-cue diver by the Professional Association of Diving Instruc-tors (PADI).

nerves of steel

P o r t r a i t t r a c i e c l a r K e

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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 an-swered, “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 ac-counts within the NAFTA market, including GE, Volvo, Siemens, Stryker and Rolls-Royce. She is also responsible for Seco Business Solutions, the

Pricing Intelligence group and the development of a full partnership package for NAFTA. Moreo-ver, 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 dis-cussion 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.”

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.

Never pretend to know some-thing you don’t. Trust is the key to strong business relationships. People buy from people – under-

stand your customers’ needs, and deliver winning solutions.

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

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 replace-able 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

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…

storythe minimaster

TexT Åke r Malm PhoTo jonas gauffin

Bengt Strand came up with the idea for Minimas-

ter back in 1983.

P r o d U C t s m i n i m a s t e r P l u s

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

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 re-ally 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 Ber-glöw 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.

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

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P r o d U C t s m i n i m a s t e r P l u s

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: Mayorder & application data: Minimaster Plus catalogue

With the launch of Minimaster Plus, copy-milling technology takes another leap for-ward. A new insert design offers higher pro-ductivity and finer tolerances with the same flexibility as its renowned predecessor.TexT Åke r Malm

the ne xt generation

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 replacea-ble 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 produc-tion. He and his colleagues made a few proto-types 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 Anders-son. “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 press-ing the inserts to the grinding machines that sharpen them. Eventually, Minimaster Plus was ready for lab tests. At the end of 2010 it under-went 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 pro-gramme, to be followed by an extended selec-tion of inserts and shanks in two steps.”

Users of Minimaster need to get new shanks to benefit from the additional precision and pro-ductivity offered by Minimaster Plus.

ThE ChAllEngE FACIng Pre-study Manager Christer Jönsson and his team wasn’t an easy one: Develop a new generation of Seco’s suc-cessful Minimaster series. Since its 1987 launch, Minimaster had taken a lead position in end-milling 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 preci-sion,” says Jönsson, who is now Corporate Prod-

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

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everybody winsMichael Richardson, Managing Director of Advanced Cutting Tools Ltd, takes advan-tage of Seco’s PCA programme to improve his customers’ bottom line.

PhoTo Mishka henner

MIChAEl rIChArdSon

Age: 39occupation:

Managing Director, Advanced Cutting

Tools Limitedlocation:

Gateshead, UKFamily: Wife

Interests: Mountain biking in

Scotland and Kielder, England

Productivity & Cost Analysis (PCA)Seco’s PCA system takes a wide view of cus-tomers’ manufacturing, focusing not just on tool-ing 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

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 so-lutions 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.

o n t h e j o b

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wITh ThE lAunCh oF A rAngE of Jabro high-performance tools, titanium and heat-resistant super-alloys (hRsa) can now be machined with specially designed tools. Jhp770 is designed for work on tita-nium, 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 vibra-tion 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

taking on titanium

Small wonderU n a l l o y e d s u c c e s s w i t h a l l o y sFor SuPErAlloyS and titanium alloys used in the aerospace, energy and medical technology industries, high-performance profiling requires special tools. that’s where Rp chipbreakers come in, the latest addition to seco’s multi-directional turning (mDt) prod-uct 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-fer-rous 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 Jet-stream tooling high-pressure coolant.

www.secotools.com/ rp_chipbreakers

www.SECoToolS.CoM Product availability: now order & application data: Mn update 2011

MdT 2MM ExPAndS the capa-bilities of Seco’s multidirectional turning (MDT), grooving and part-ing-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 stabil-ity 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

TexT graeme Forster

i n b r i e F

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ThIS SPrIng, SECo CuS-ToMErS 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 functionali-ties 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 comple-ment Seco’s threading products.

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

A software revolution

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 Jet-stream tooling coolant delivery sys-tem 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,

cp500 and tm4000 grades, together with two new seco cermet grades: tp1020 and tp1030.

tp1020 is an uncoated cer-met insert for demanding sur-face-finish applications with low cutting data in steel and stain-less 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.

steel away

i n b r i e F

a t o o l f o r e v e r y C o m P o s i t eThE 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

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the new JabRo-soliD2 prod-uct family for general machining applications is welcoming a new member: Jabro-solid2 Multiflute. Designed for all high-quality sur-face 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 materi-als – 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.

the magic

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.

Personal assistant

Get a gripThE BETTEr ThE ClAMPIng of the tool, the higher the speed and the better the results, particularly with long machining times. a new, ready-to-use device called easyshrink® 15 achieves fast and economical shrink grip and shrink release for all shank material types. it gives operators the oppor-tunity 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.

m U l t i f l U t e

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6mm

Condyle tool

Solid carbide endmill: produces the full profile of the femoral component

Custom form end mill: produces ultra-smooth bearing surface8mm

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

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.

joint venture

the PerfeCt