https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/11/10144131/42-44-20-715-Ceratizit-Freeturn-Tool-MR-640x360.jpg
    Tooling

    Shorter production times, and lower tool costs!

    • By CERATIZIT UK & IRELAND LTD
    • November 22, 2020
    • 4 minute read

    Only those who rely on advanced and future-oriented tool solutions can remain competitive in the long term. For this reason, those responsible at the CERATIZIT production site in Besigheim have decided to use the new High Dynamic Turning (HDT) technology and the FreeTurn tools in the production of their high-quality tools.

    Since its unveiling at AMB 2018, the High Dynamic Turning (HDT) process has made waves in the world of machining. By using the milling spindle in turn-mill centres, the cutting angle of the dynamic FreeTurn tool can be adjusted 360° for optimal use in every position of the workpiece. This creates several opportunities. First, flexible machining of almost any workpiece contour is possible whilst chip breaking can also be optimised. It is even possible to achieve higher feed rates and tool life with maximum stability using the dynamic turning method.

    Is the change to HDT with FreeTurn worth it?

    Presenting a turning tool to the workpiece using a milling spindle at first sounded like science fiction to traditionalists, but it is now a reality. The new process and the dynamic FreeTurn tools are now being adopted by more and more manufacturing companies. Dr Thomas Ledermann, the production manager for special tools at the CERATIZIT tool manufacturing location in Besigheim was keen to put the revolutionary turning process to the test. “The possibilities offered by High Dynamic Turning and FreeTurn appealed to us. Therefore, we decided to implement the turning process to test whether it does what it claims.”

    The possibility of a tooling reduction was particularly exciting because a single FreeTurn indexable insert can be used for various applications. For Mr Ledermann, this fact alone is a good argument for switching to HDT, as it saves considerable tool costs.

    “The most obvious advantage of HDT and FreeTurn is the tool cost savings. Where we conventionally needed several tools for roughing, finishing, contour, face and longitudinal turning, we now only need one dynamic FreeTurn tool,” says Paul Höckberg, Product Manager for Turning at CERATIZIT, who assisted the changeover at Besigheim. However, when using FreeTurn at Besigheim, it was quickly realised that this is not the only advantage. In terms of process speed and energy efficiency, too, the dynamic turning process was ahead of conventional machining.

    “The initial machining at Besigheim was conducted on a DMG MORI CTX beta 1250 TC as it fulfils all the requirements for turning in a highly dynamic manner. This machine is widespread on the market and HDT ready, confirming that many manufacturing companies can use our FreeTurn technology,” says Paul Höckberg. The component is chosen, a base body of an indexable insert drill is then optimised and programmed using the Siemens Sinumerik 840d controller and 5-axis simultaneous cycle software from OPEN MIND – the results are astonishing.

    “As expected, we were able to reduce the number of tools required. Instead of three different tools, we now manufacture the component with one FreeTurn tool,” says Ledermann. What stood out to the experienced production manager was the cutting data. “We processed the component with a cutting speed of VC220m/min, a feed rate of f0.48mm/rev and an infeed depth of ap4mm. For finishing cuts, the surface speed increased to 400m/min. FreeTurn proved itself to be a far superior alternative to our conventional tools,” summarises Thomas Ledermann.

    Surprisingly, Paul Höckberg was also amazed by this result: “We knew FreeTurn was good. However, we would never have thought it possible to drive such enormous cutting speeds in mild steel. We were able to save 2.25 minutes of production time, 3.53 Euros production costs and 0.42kW/h of energy per component”.

    Due to this positive result, High Dynamic Turning and FreeTurn will certainly find its way into everyday production at Besigheim. Programming is carried out using the CAD/CAM software Siemens NX, which is also ideal for HDT. “We are already looking forward to gradually converting our production to High Dynamic Turning and FreeTurn,” says Thomas Ledermann. “This way we can secure a significant competitive advantage.”

    https://cdn.mtdcnc.global/cnc/wp-content/uploads/2020/11/10144131/42-44-20-715-Ceratizit-Freeturn-Tool-MR-640x360.jpg

    Shorter production times, and lower tool costs!

    Only those who rely on advanced and future-oriented tool solutions can remain competitive in the long term. For this reason, those responsible at the CERATIZIT production site in Besigheim have decided to use the new High Dynamic Turning (HDT) technology and the FreeTurn tools in the production of their high-quality tools.

    Since its unveiling at AMB 2018, the High Dynamic Turning (HDT) process has made waves in the world of machining. By using the milling spindle in turn-mill centres, the cutting angle of the dynamic FreeTurn tool can be adjusted 360° for optimal use in every position of the workpiece. This creates several opportunities. First, flexible machining of almost any workpiece contour is possible whilst chip breaking can also be optimised. It is even possible to achieve higher feed rates and tool life with maximum stability using the dynamic turning method.

    Is the change to HDT with FreeTurn worth it?

    Presenting a turning tool to the workpiece using a milling spindle at first sounded like science fiction to traditionalists, but it is now a reality. The new process and the dynamic FreeTurn tools are now being adopted by more and more manufacturing companies. Dr Thomas Ledermann, the production manager for special tools at the CERATIZIT tool manufacturing location in Besigheim was keen to put the revolutionary turning process to the test. “The possibilities offered by High Dynamic Turning and FreeTurn appealed to us. Therefore, we decided to implement the turning process to test whether it does what it claims.”

    The possibility of a tooling reduction was particularly exciting because a single FreeTurn indexable insert can be used for various applications. For Mr Ledermann, this fact alone is a good argument for switching to HDT, as it saves considerable tool costs.

    “The most obvious advantage of HDT and FreeTurn is the tool cost savings. Where we conventionally needed several tools for roughing, finishing, contour, face and longitudinal turning, we now only need one dynamic FreeTurn tool,” says Paul Höckberg, Product Manager for Turning at CERATIZIT, who assisted the changeover at Besigheim. However, when using FreeTurn at Besigheim, it was quickly realised that this is not the only advantage. In terms of process speed and energy efficiency, too, the dynamic turning process was ahead of conventional machining.

    “The initial machining at Besigheim was conducted on a DMG MORI CTX beta 1250 TC as it fulfils all the requirements for turning in a highly dynamic manner. This machine is widespread on the market and HDT ready, confirming that many manufacturing companies can use our FreeTurn technology,” says Paul Höckberg. The component is chosen, a base body of an indexable insert drill is then optimised and programmed using the Siemens Sinumerik 840d controller and 5-axis simultaneous cycle software from OPEN MIND – the results are astonishing.

    “As expected, we were able to reduce the number of tools required. Instead of three different tools, we now manufacture the component with one FreeTurn tool,” says Ledermann. What stood out to the experienced production manager was the cutting data. “We processed the component with a cutting speed of VC220m/min, a feed rate of f0.48mm/rev and an infeed depth of ap4mm. For finishing cuts, the surface speed increased to 400m/min. FreeTurn proved itself to be a far superior alternative to our conventional tools,” summarises Thomas Ledermann.

    Surprisingly, Paul Höckberg was also amazed by this result: “We knew FreeTurn was good. However, we would never have thought it possible to drive such enormous cutting speeds in mild steel. We were able to save 2.25 minutes of production time, 3.53 Euros production costs and 0.42kW/h of energy per component”.

    Due to this positive result, High Dynamic Turning and FreeTurn will certainly find its way into everyday production at Besigheim. Programming is carried out using the CAD/CAM software Siemens NX, which is also ideal for HDT. “We are already looking forward to gradually converting our production to High Dynamic Turning and FreeTurn,” says Thomas Ledermann. “This way we can secure a significant competitive advantage.”