It’s Tool Time

‘It’s Tool Time’ is a new initiative focused on showcasing Ceratizit’s new products and innovations to a global audience without participants ever having to leave the comfort of their homes or offices.

And that’s because it’s entirely virtual. At the inaugural November 2020 launch, presentations moved seamlessly across a wide range of topics, products, conversations and different locations. Holding it all together admirably was presenter Harald Greising. The intention is to hold these informative events on a regular basis.

The Ceratizit Group has expanded significantly in recent years. Kicking off ‘It’s Tool Time’ Thierry Wolter, member of the group’s executive board comments: “Group development has been very good over the past decade. We have grown tremendously – both organically and via acquisitions. Today, globally, I would say we are currently No. 4 in the carbide industry – and definitely in the Champions League!”

Combined, the group brands comprise: Ceratizit for indexable insert tools for turning, milling and grooving; Komet for high precision drilling, reaming, countersinking and boring; WNT specialising in rotating tools, adapters and workholding solutions; and Klenk for solid carbide tools for the aerospace industry.

Mr Wolter accepts that COVID-19 has had a negative impact on business but he remains upbeat: “To be honest, the downturn, particularly in the automotive sector, started before the Coronavirus crisis so we weren’t taken entirely by surprise,” he recalls.

“We’ve used the time wisely by focusing even more on the customer. Digitisation began at Ceratizit a long time ago and since COVID everything has accelerated. As a privately owned, financially strong business, we’re well-equipped to ride the storm and emerge stronger.”

Turning with a twist

High on the ‘It’s Tool Time’ agenda and undoubtedly one of the biggest product announcements to emerge from the Ceratizit stable in recent years is High Dynamic Turning (HDT) with FreeTurn tools. Unveiled a couple of years ago, it’s been gaining pace like a freight train ever since.

This innovative process enables all familiar turning operations such as roughing, finishing, contour turning, facing and longitudinal turning to be completed with a single tool. Dr Uwe Schleinkofer, director, Ceratizit R&D takes up the story.

“We believe HDT with FreeTurn is truly revolutionary for the machining industry, primarily because it frees us from the restraints of conventional 2-axis turning,” he explains. “With HDT we use multi-purpose machines and bring the Y-axis and milling spindle into play to control the cutting tool. This means we can change the tool’s approach angle on the workpiece directly during the cut and drastically reduce both the number of tools required and the cycle time.”

In Ceratizit’s Technical Centre, a DMG Mori CTX Beta 1250 TC 4A is used to demonstrate the full potential of FreeTurn. It’s a free system and mutual collaboration with other companies is actively encouraged – in fact its success depends on it. Recent contributors and partners include Heidenhain and CAD/CAM developer Open Mind.

“FreeTurn is so important to us that we’ve built a brand-new Technical Centre in Paris around its application,” Mr Wolter adds.

New product introduction: WTX HFDS (High Feed Drilling Steel) drill

Felix Meggle, team leader, product management industry solutions at Ceratizit says the WTX HFDS is the first drill with four cutting edges and four coolant holes on the market, and is designed specifically for steel and cast iron.

Available in diameters from 6-16mm, the new drill features Ceratizit’s DPX14S Dragonskin coating which exhibits a very low coefficient of friction, guaranteeing long tool life and high cutting speeds. Pyramid shaped point thinning adds to its stability and accuracy. It has a positional accuracy of approximately 0.03mm

But what about chip volume? “Chip volume depends on the feed rate, and the feed rate, with four cutting edges is very high,” Mr Meggle explains. “We can achieve feed rates up to 65% higher than a drill with two cutting edges depending on the machining parameters, the machine tool itself and material being cut.

“For example, with 42CrMo4 tempered steel alloy heat treated alloyed steel, we are able to run an 8mm diameter WTX HFDS drill to a depth of 5 x diameter at 80-100m/minute cutting speed with a rotational feed rate of 0.5 - 0.9mm/revolution. Pretty impressive.”

Product focus: Multilock exchangeable head system

In January 2020, Ceratizit launched a new exchangeable, precision sintered head system called Multilock. According to product manager Michael Wucher, there were clear reasons behind its development.

“Many exchangeable head systems on the market today have the same problem – they have very complex, precision designed interfaces and take a lot of time to manufacture,” he explains. “With the Multilock we created a very cost-effective system – it doesn’t require grinding after the sintering process which saves a lot of time and resources.

“The Multilock is a very sustainable tool. We can save around 70% manufacturing time and approximately 80% in terms of the carbide used – savings that we can pass onto the customer. Also, a wide range of adapters are available.

“In terms of the materials that can be machined with the system, we have two carbide grades in our portfolio: one is designed for machining steel and cast iron and the other is for processing titanium and titanium alloys.”

New product introductions: CTCM turning grades for stainless steel machining

In September last year, Ceratizit expanded its turning range with stainless steel inserts CTCM120 and CTCM130 complementing the existing CTPM125 universal grade. Now the company has developed a more wear resistant version – CTCM120 for austenitic steels and a tougher option CTCM130 for when taking interrupted cuts.

All grades are combined with Ceratizit’s Dragonskin coating for high performance, long tool life and process security. It also ensures efficient layer adhesion to the base substrate and prevents layer chipping.

Brian Lorenzen, Ceratizit’s marketing services manager elaborates: “We have a large range of positive and negative turning inserts with different chipbreakers for finishing and medium rough machining. Depending on their application, customers can choose from three geometries for negative indexable inserts or two positive inserts across all three cutting material grades.

“For optimum insert performance, it’s necessary to have coolant directed at the main cutting edge. Our new range of PSC toolholders used together with our direct cooling system, can increase tool life up to 100% and improve chip control.

“We are also pleased to introduce two new products available now from Ceratizit’s online store: high performance boring bars with exchangeable cutting heads and a vibration dampening adapter.”

New product introduction: CTCM245 high performance grade

“Many things work better as a team and with this in mind, Ceratizit has developed a new grade for high alloy steels that features an optimised coating and substrate combination,” reveals Ceratizit product manager, Robert Frei.

“Users benefit from high cutting speeds when dry machining materials containing chromium, such as tool steels, martensitic stainless steels, and high-alloy austenitic stainless steels, which are difficult to machine because of their inherent high ductility, their tendency to stick to the tool and work harden, and their low heat conductivity.”

CTCM245’s properties make it suitable for dry machining which means thermal shocking can effectively be prevented. It also has high temperature resistance which means higher cutting speeds can be used. The new grade is available in a range of insert shapes from round to square to octagonal.

“The layer combination is particularly significant,” Mr Frei adds. “CTCM245 uses a triple layer chemical vapour deposition (CVD) process in which each layer is a high performer in its own right. But combining them takes things to another level in terms of enhanced tool life and performance, temperature resistance, reduced flank wear and hardness to resist breakage.”

New product: X5G-Z 5-axis vice

Live from Ceratizit’s Technical Centre in Kempten, product manager Christoph Retter presented a brand new 5-axis vice – the X5G-Z – offering five-to-six-sided machining in a single clamping device.

Standout features include: excellent accessibility; a 130mm clamping stroke; quick change jaws (in just a few seconds with no specific tools required); 40kN clamping force; integrated pull-down; and a quick-change spindle. 14 quick change jaws are available in widths of 40mm/65mm/80mm and 125mm.

“The X5G-Z is available in two different heights: 175mm and 240mm and five different body lengths: 330mm up to 800mm. We can deliver the vice from stock within 24 hours,” Mr Retter says.

“We also integrated elastomers into the base jaws to minimise vibration. The X5G-Z is totally compatible with Ceratizit’s MNG zero-point clamping system and installation is quick and simple.”

New product: new version Monstermill PCR endmill

“Designed for a multitude of applications, our Monstermill product range is well-established but with this new version we wanted to make it even more multi-functional,” explains product manager Michael Wucher. “The challenge was to find the perfect carbide grade to accommodate different cutting forces whilst maintaining high levels of flexibility. With the new version, I think we’ve achieved that objective.”

The new PCR Monstermill can be used for drilling, diving, ramping, trochoidal milling and HPC milling, uncompromised and from a single tool. It incorporates a special patented face, core, and cutting-edge geometry. The carbide grade lends itself particularly well to trochoidal milling and represents a fine balance between toughness and strength. Special attention was also paid to the bending characteristics of the carbide grade selected.

Two variants are available: one for steel and cast iron, the other for aluminium.

Ceratizit www.ceratizit.com