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Hard part turning with high feed rates

Component: Gear
Material: Case-hardened 04.1 (58–60 HRC)
Operation: Longitudinal turning
Machine: Weisser MC-1

+257%
Metal removal rate

Competitor Sandvik Coromant
ToolQS-LF123G15C2525E
InsertN123G1-0300S01025-XB 7105
vc m/min (ft/min)190 (623)120 (394)
fn mm/rev (in/rev)0.15 (0.006)0.6 (0.024)
ap mm (inch)0.15 (0.006)0.15 (0.006)
Tool life criteria, Ra, µm (µin)0.6 (23.6)0.6 (23.6)
Number of components600300/profile x 2 (profile 1 and 2) = 600
MRR cm3/min (in3/min) 4.2 (0.256) 10.8 (0.659)

Screw clamping vs. spring clamping

Theory confirmed in practice

Longitudinal turning operation tests confirmed that the new rigid spring clamping allowed for a feed rate* increase of 27% with maintained deflection. This proves the high rigidity of the spring clamping system.

Vibration deflection test

By applying a force (N) on the insert edge, the dynamic flexibility was measured at the vibration point, in terms of deflection per force unit (m/N).

Results With spring clamping With screw clamping
Deflection (m/N)1.69×10-54.56×10-5
Enabled feed rate increase27%-

*Do not exceed cutting data recommendations for your insert. Also take machining conditions in consideration.

Parting off bar

The use of a CoroCut 1-2 QS shank featuring internal over- and under coolant (9 bar, 131 PSI) gave an tool life increase of 500% and a productivity increase of 34% compared to the competitor tool using external coolant.

Operation:Workpiece material
Parting off bar, Ø25 mm(0,984 inch): Stainless steel, M1.0.Z.AQ (200HB)
Tool:QS-LF123G20C2020F
Insert:N123G2-0300-0002-CM 1145

Cutting data CoroCut 1-2 Competitor
vc m/min (ft/min)90 (295)90 (295)
fn mm/r (in/rev)0.1 (0.004)0.08 (0.003)
 
Results CoroCut 1-2 Competitor
Tool life pcs900150
Productivity increase34%-

Parting off square bar

The use of a CoroCut 1-2 tool together with internal coolant supply (8 bar, 116 PSI) gave a tool life increase of 50%, compared to the competitor tool with external coolant supply.

Operation: Workpiece material
Parting off 10 mm (0.4 inch) square bar: Nickel based super-alloy, S2.0.Z.AN
Tool:QS-RF123G15C2020E
Insert:N123G2-0300-0002-CM 1145

Cutting data CoroCut 1-2 Competitor
vc m/min (ft/min)17 (56)17 (56)
fn mm/r (in/rev)0.04 (0.0016)0.04 (0.0016)
 
Results CoroCut 1-2 Competitor
Tool life pcs1510

GC4325 in CoroCut® 1-2

Using the same cutting data and the same CoroCut 1-2 tool in this roughing operation, tool life increased with 92 percent when changing the insert grade from GC4225 to GC4325.

Operation: Component
Grooving: Outer bearing ring
Workpiece material: Steel, P2.1.Z.AN, CMC 02.1

+92%
Increase in tool life
Cutting dataN123H2-0400-0008-TM
vc m/min (ft/min)350 (1148)
fn mm/r (in/rev)0.15–0.24 (0.006–0.009)
 
Results GC4325, CoroCut 1-2 GC4225, CoroCut 1-2
Tool life pcs4825

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