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Vibration-free through Slotworx® M - High-Feed-Geometries 20.07.2010 Job title: Optimization of a machining operation at the Hofmann Modellbau GmbH for a component from material 1.1730 | Ck45, an easy machinable cold work steel with 640 N/mm² tensile strength, which is used for mounting-bases in framework-, jigs- and fixtures-construction in most cases. The HIG – Hofmann Innovation Group, founded in 2003, is the holding organization for 6 companies, and Hofmann Modellbau GmbH is one of their members. HIG achieved with more than 460 employees and 15.300 sqm. of production area a turnover of more than 42 Mio. € in the year 2002. The Hofmann Modellbau GmbH, founded in 1990, is the second largest commercial line of the group, employing 120 staff members. The model-making branch hits the line hard in using new high-speed & feed technologies for achieving cost advantages and thus, success on the market. They have very special know-how in small lot- and initial sample production. The component to be machined has blank-dimensions of 120 mm length and 90 by 90 mm width and height and has been machined up to today with a high-feed milling cutter of 25 mm diam. and a theoretical corner radius of 2 mm. With this tool, only minimum depth-steps of ap <=0.4 mm were possible. Anything higher than that was creating vibrations due to increased cutting pressure and this was leading to machine down-times, because the vibration measuring device stopped the machine from time to time. Unattended shifts were impossible. In the long run, this was a very negative effect for the roughing operation. Our applications engineers have tried our new indexable inserts from our Slotworx®-M-range. The selected milling cutter 3 25 267 (diam. 25) has outperformed excellent on this job. Together with the latest insert 04 67 848 HF, developed especially for shallow cutting depths and high feed rates, this challange has been solved. Due to the positive cutting geometry of the milling cutter body and the slight positive rake angle of the insert, distinct reduction of cutting pressure and at the same time, increasing of chip volume has been possible. For this one and for many other applications, these new inserts with HF-geometries from the Slotworx®-range are the ideal solution. Due to the optimized macro-geometry, the larger corner radius and the 95° setting angle in the milling cutter body, these tools should be used where every other square-shoulder and slot-milling cutter have reached its limits.
This component has been produced in climb-milling, z-constant and parallel to the axis. Looking to the resulting machining time, feed rate and thus chip/time-volume has not been increased significantly, however, this complete component has been produced without any down time. Through the particular form of the Slotworx®-M-inserts, the chips were under very good control and excellent removal, even in cutting widths of ae = 100%. example from practice: 
Result: No interfering vibrations have stressed the machine. Less machining allowance, reduced tool wear and reduction of typical production shop floor sounds and further positive attributes when using these new inserts. Enough positive potential for a future cooperation with the outstanding tools from Pokolm Frästechnik GmbH & Co. KG from Harsewinkel. They have set the course for a prosperous future with Pokolm-premium-tooling. Print page |
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