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LMT Tools magazine 2017/2018

Drive Silently into the future Medical technology High-tech inside the body Ascending force: a demanding challenge Highlights 2017 3 EDITORIAL CopyMax®1 ACU-Jet Double6 Premium 4 EX ACTLY YOURS Light and efficient copy milling cutters: The new Roughing endurance: With its indexable inserts and six is changing indexable insert CopyMax®1 is the latest addition cutting edges, which can be used on both sides, the to the CopyMax® product family. Depending on the ACU-Jet Double6 milling system significantly increases the 6 TOPIC OF THE DAY: DRIVE TECHNOLOGY application, manufacturers can now use either the tool life during roughing. Thanks to an optimized base plate 6 Silently into the future one-sided or the existing double-sided CopyMax®2 and newly designed indexable insert, the ACU-Jet Double6 8 Upgrade for Downsizing indexable insert. They provide a longer tool life, while Premium can increase its performance lead over the Dear Reader, requiring less tool handling time. competition. 10 TOPIC OF THE DAY: MEDICAL TECHNOLOGY Page 16 Page 18 Welcome to the new edition of your High-tech inside the body exactly yours customer magazine. 12 TOPIC OF THE DAY: AEROSPACE 12 Ascending force: a demanding challenge On 1 May 2017, I took over responsibility for the leadership 14 Quick and reliable of LMT Tools. Since then, I have had many interesting at Premium AEROTEC conversations with you, our customers and partners as well as the employees of LMT Tools. There was a common 16 MILLING HIGHLIGHTS theme in all these conversations: We are living in a period 16 Mold twice as easy of major changes – social, economical as well as tech- 18 More efficient by the dozen nological changes. In many places, I have sensed a genuine 19 Maximum hardness curiosity for the changes that lie ahead of us and the will MultiEdge 2Feed mini with new indexable MultiFace H45 PRO4 and P45 PRO8 20 Many faces, one mission to adopt these changes to help shape the future. To insert Highly versatile: The MultiFace H45 PRO4 and P45 PRO8 accompany the technological change, to actively participate For particularly tough cases: The high-feed cutter face-milling cutters enable high material removal rates 22 THREADING HIGHLIGHTS in this and, in particular, to face the dynamics brought about MultiEdge 2Feed mini provides a large amount of chips even on lower performance machines. This is achieved Quality comes from the inside during roughing. A new indexable insert extends its with the highly positive cutting edge geometry of the by the individual developments – this is where I see a major performance range for high-strength materials. This is MultiFace H45 PRO4, which has four cutting edges per 23 GEAR CUTTING HIGHLIGHTS challenge. ensured by a special high carbide content substrate indexable insert, as well as the positive cutting edge Combines and precision and a TiAlN-based high performance coating. geometry of the MultiFace P45 PRO8 with its eight An example for this is the automotive : We are now Page 19 cutting edges. The easy cutting cutters can therefore be 24 HIGHLIGHTS creating the basis for a comprehensive electrification of used for many different applications. Rolling with precision mobility. However, at the same time, experts agree that the Page 20 development of more efficient combustion engines will be 25 ADVANCED TOOLING HIGHLIGHTS continued alongside over the coming years. Nearly all core Actuators promote precision industries face similar challenges. 26 COATING HIGHLIGHTS Progress through research As a tool manufacturer, we have positioned ourselves clearly within this environment and expressed our claim with 27 LMT TOOLS “exactly yours”. For us as a , “exactly yours” means News to focus our expert knowledge on selected niche technolo-

TOOL gies and applications and to use them with the aim to INFO provide our customers with a competitive advantage in their HPF Max UNIFY Published by: LMT Tool Systems GmbH & Co. KG, Heidenheimer Straße 84, 73447 Oberkochen, , Phone: +49 7364 9579-0 industry segment. For our customers, “exactly yours” means The HPF high-performance thread former is widely Economical and precise: The new UNIFY gear hob Responsible according to the press law: Volker Reinsch, LMT GmbH & Co. KG that they have a global, reliable competence partner for used for chip free and efficient manufacturing of female with indexable inserts extends the area of Editor-in-chief: LMT Tool Systems GmbH & Co. KG Concept and editing: SCRIPT Corporate + Public Communication GmbH, current machining as well as an attentive threads. Its successor, the HPF Max, provides even application of the CarbideLine-I (indexable) gear hob Frankfurt am Main; Prof. Dr.-Ing. Diethard Thomas higher performance. This is made possible by a new family in the module range 6-12. Its compact design, Design: Braun Engels Gestaltung, Ulm, Germany development partner for the technologies of the future at Printed by: Weidner GmbH, Rostock very fine grain carbide substrate, a new coating and a with an extremely robust base plate, enables the their side. We develop tool solutions which are exactly © LMT Tool Systems GmbH & Co. KG, 2017 newly optimized updated geometry. economical and precise use tools from a diameter Reprinting, including in part, is only permitted with our approval. tailored to our customers’ requirements. You can get insight Page 22 of 150 mm. All rights reserved. Mistakes, typesetting or errors do not give rise to into what we intend to do and what we can do for you on any damage claims. Any fi gures, descriptions and dimensions were Page 23 up-to-date at the time of printing the following pages. Technical modifi cations are reserved. The pictorial representation of the products does not necessarily match their actual appearance in each case and in every detail. Enjoy the read. Picture : Dominik Obertreis Fotoreporter, Althütte-Waldenweiler: p. 3, 24 FOTO DIETERLE – Oliver Wernert, Lahr: p. 9 Yours sincerely, Daniel Ehmans Fotolia: p. 10, 11 (alarico73, Alexandr Mitiuc, iaremenko, monstarrr), Executive Board LMT Group p. 12 (Juice Images), p. 22 (Korshenkov) Hannes Werner, LMT Tool Systems GmbH & Co. KG, Oberkochen: p. 1, 23 Division President LMT Tools Karsten Socher Master photographer/photo journalist, Kassel-Nordshausen: pp. 11, 21, 23, 25 LMT Belin S.A.S, Lavancia: p. 13 LMT Fette Werkzeugtechnik GmbH & Co. KG, Schwarzenbek: p. 24 LMT Group GmbH & Co. KG: p. 27 LMT Kieninger GmbH, Lahr: pp. 8, 9, 17, 25 Premium AEROTEC: p. 14, 15 Studio Thomas Schmitz GmbH: pp. 2, 7, 8, 9, 10, 13, 16, 17, 18, 19, 20, 21, 22, 23 ZF Friedrichshafen AG: p. 6 3 We asked these LMT Tools experts:

exactly yours Leslie Banduch CEO LMT Onsrud

Thomas Falk Manufacturing is changing Head of the Gear Cutting segment Jochen Jäger Manager Europe

The manufacturing industry is in transi- How are the customers Jürgen Richter tion. But what do the changes mean accepting the offer? Head of the Advanced Tooling segment for a tool manufacturer like LMT Tools Center of Competence David Szillat and how does the company respond David Szillat: Our Center of Competence EUROPE Head of the Rolling segment to the changes in users’ requirements? in has had a sensational start. In the run-up to EMO 2017, we asked We were able to acquire numerous new Siva Venkat experts from LMT Tools’ international customers who used to cut their threads Center of Competence CEO LMT USA team how they assess instead of rolling them. This has been CHINA the current development and how the successful in two ways. Customers have Jörg Wuttke company is preparing for it. not only accepted us as a new provider, Center of Competence CEO LMT Fette but also changed their technical method. USA Werkzeugtechnik Mr. Wuttke, LMT Tools announced in This can only be achieved if there 2016 that they would set up Centers are competent colleagues locally who are of Competence across the world. What familiar with the requirements and the does this term mean and how far did culture. you get with the implementation? Why does LMT Tools need this local Center of Competence Jörg Wuttke: With our Centers of Compe- expertise? tence, we offer to our customers a unique model which uses individual contact Jürgen Richter: The individual regions persons who provide direct access to all and markets are very different with our core competencies. The individual regard to their qualification, capacity and contact persons analyze our customers’ . The Centers of Compe- requirements and develop the best tence in the core markets have been fully solution for each case in cooperation with adapted to the cultural circumstances their colleagues from the international and country-specific rules, the employees network of LMT Tools. In Europe, in the know the local market. US, in China and in India, the Centers Mr. Jäger, in the past LMT Tools strongly Mr. Venkat, how is the manufacturing our customers during this modernization composites. This is a subject in the aero- are integrated into our existing locations Thomas Falk: To be successful, you do focused on the machining of entire industry in the US developing? as partners making the know-how gained , in particular. However, and they are made up of three compe- not only need to provide better technology, components. What happened to this from these projects available worldwide via the is also constantly tency teams: Gear cutting, rolling but also have to be quicker. This is what orientation? Siva Venkat: our Centers of Competence. moving in this direction, the keyword and components. In the components we experience in China and in other We are experiencing major changes in the is light-weight design. A few years ago this team, we have combined the three international markets. Our new structure Jochen Jäger: We continue to pursue this demand behavior of our customers, Mr. Banduch, how do you perceive the was slow to get off the ground, but the segments Milling & threading, Reaming enables us to process many subjects intensively. We are concentrating on particularly in manufacturing. But changed requirements of customers at demand for corresponding solutions is and Advanced Tooling as the require- locally and independently and to provide a the areas of medical technology and aero- we are also seeing a change in the LMT Onsrud? now growing rapidly. ments tend to be similar for these. We quick solution. And for the really complex space as well as selected components aerospace industry and in medical techno- continue to develop this structure. subjects, the customers take the time to in the automotive industry. This is what logy. The renewed growth in the manu- Leslie Banduch: We are very close to our come to Europe themselves. stands behind the Components Compe- facturing industry in the US – some even customers and they have great confi- tence team. This is already a success for call it a reindustrialization – is linked to dence is us. For us, this is the basis from us. For instance, we were able to offer systematic modernization. This means that which we take the next steps. Specifically, a complete solution for reputable auto- production is increasingly automated. for major customers, we will be integrating motive suppliers in close cooperation with Modern machine tools and machining programming experts into the customer the Advanced Tooling segment includ- tools, which enable users to fully utilize the teams in the future. They need this knowl- ing milling and threading tools, enabling capabilities of these machines, will play a edge today to optimize their processes the users to machine turbochargers and/or major part here. We will be accompanying further. Another area in which we invest in differential housings. a targeted manner is the development of tools which enable users the processing of new high-performance plastics and

4 5 Topic of the day: Drive Technology

In this example, the powertrain of the was located between the two wheels in a very tight space which included the Silently into electric motor, the gearbox and the inverter, which converts direct current to alternating current in one single unit.

Thomas Falk the future The dimensions of the gears were similar to those in the gearboxes Head of the Gear Cutting segment of conventional cars. However, to meet the increased requirements [email protected] with regard to noise levels, extremely high precision was required. 8-Speed plug-in This is why the gearbox manufacturer chose the tool system gear hybrid gearbox at hob plus ChamferCut. ZF Friedrichshafen Projected market development In cooperation with Liebherr, the gear cutting machine manufac- of different vehicle powertrains turer in Kempten, LMT Fette has brought the milling system worldwide in percent ChamferCut to perfection. This system enables the chamfering of toothed wheels directly after hob cutting. ChamferCut can either Electrical powertrain be fastened onto a mandrel together with the gear hob or it can be used as an individual tool on a separate milling spindle. In either Hybrid powertrains case, the result is a high-precision, consistent chamfer on the gears. Combustion engine only

For the gearbox in the electric car, this high chamfer quality plays 100 an important part in achieving low noise levels. The cutting 95 % per gear could also be markedly reduced as a second required gear cutting step such as press deburring could be elliminated. 90

80 72 %

70

60 51 %

50 44 % 39 % Electromobility is growing with big strides. However, One of the pioneers of electromobility is an American car 40 the opinions of experts on exactly how the market is going to manufacturer which includes gears provided by another 31 % develop are currently divided. How quickly the automotive supplier using LMT Fette gear systems. There is a strong 25 % 30 industry can achieve its ambitious targets depends on how focus on one quickly the technological requirements can be implemented subject – noise levels. 25 % 20 and what will be specified by policy makers. According to 10 % an internal study of the LMT Group, approximately 25 percent The known performance characteristics for gearboxes such as 4.6 % 10 of all new cars will only have an electric powertrain by 2030. long life as well as optimum dynamic behavior still apply. 3 % Another 31 percent will be different hybrid versions. However, in contrast to a combustion engine the electric motor 0.4 % is virtually silent. To ensure a smooth and noise free ride it must 0 2015 2020 2025 2030 As a recognized partner of the automotive industry, LMT Tools run more quietly in the future. contributes know-how and efficient tool systems to manufacture components used within electromobility devices. The chamfer quality is crucial Source: internal study, LMT Group Currently, the focus is on modern gearbox technology for both In the beginning, the above manufacturer experimented with hybrid drives and for the machining of gears for which two-speed gearboxes for cars which only had an electric only have electric powertrains. The latter also require gearboxes, powertrain. This had advantages when accelerating from albeit with fewer stages. LMT Tools meets this challenge 100 to 200 km/h. Having issues delivering sufficiently powered with innovative gear systems which are developed in close and durable gearboxes, they decided to utilize The gear system consisting of gear hob cooperation with our customers. An example is described a single-speed gearbox. and ChamferCut ensures the highest quality at reduced costs per piece. in the following.

6 7 Topic of the day: Drive Technology Upgrade to downsizing Jürgen Richter Head of the Advanced Tooling segment, [email protected]

For a number of years, “downsizing” has been a trend in The concept and design of special tooling solutions supplied by automotive production: Engines have become smaller and LMT Tools are adapted to the demanding materials and molds of lighter, while delivering higher performance. One answer to this the turbocharger production. With this special focus on the challenge is the turbocharger. Inside the turbocharger, the component and the customer’s requirements, LMT Tools delivers impeller turns at a rate of up to 290,000 revolutions per minute. performance which fully meets the claim “exactly yours”. It generates extreme temperatures, which requires highly A special combination tool by LMT Kieninger can be used, for heat-resistant materials. instance, to manufacture complex contours such as the trumpet shape made on a multi-functional machining center. Bore, face The manufacturing of turbochargers is, therefore, extremely and circular mill with a single tool. demanding for the tools and the cutting materials, making it one The material and the precision of the of the most costly automotive parts to produce. LMT Tools offers Another tool example is the facing head. It makes the undercut turbocharger place extremely high high-precision end facing sliding tools and combination tools on the outer surface of the V-band, the trumpet shape demands on the tool for the production of this technically complex component. These while profiling the inside surface. systems. tools increase process reliability and reduce production costs.

Production of the turbocharger engages almost every machining operation: rough and fine machining during milling and boring as well as during threading and reaming. Highly heat-resistant materials – such as cast steel 1.4837 and 1.4848 – place high demands on the cutting material, the cutting edge geometry, the cutting edge preparation, and on the coatings of the indexable inserts. Combination tools from LMT Tools allow for fast and process-reliable machining within a single step. Different steps – boring, face and circular milling – are accomplished with a single tool. Time-consuming tool changes – a potential source of errors – are eliminated. This reduces secondary process times and increases process reliability. The tool solutions supplied by LMT Tools increase the profitability of turbocharger production by significantly reducing manufacturing costs. The facing head enables different rotary machining operations on a single machining center.

For the manufacturing of turbochargers, LMT Tools offers special combination tools for the precise machining of highly heat-resistant materials.

8 9 Topic of the day: Medical Technology High-tech inside the body

Mark Flommer Medical technology is one of the most Product manager for carbide milling, innovative and dynamic manufacturing [email protected] sectors. Its market volume is around 300 billion Euros worldwide .1 The US leads this sector with a market share Materials which are difficult to machine of 38.8 percent, followed by China Materials for joint replacements must be resistant to fatigue, with 12.2 percent and Germany with to corrosion, and need to be biocompatible. They must not cause 9.3 percent. The are many indications any negative effects when they are in contact with living tissue. that medical technology remains a global High-strength ISO-S materials are primarily used for this economic driving force: the world application, including the titanium TiAl6V4 or cobalt- population is growing, life expectancy chromium-molybdenum (CoCrMo). Titanium has a very high is rising and a high quality of life in old tensile strength. This is perfect for the life of the prosthesis, age is expected. but makes machining extremely difficult. Due to the high heat resistance of the titanium material, the heat does not transfer into This requires solutions which counteract the chip or the material during machining, but into the tool. To the natural wear of bones and joints reduce wear, LMT Tools uses carbide tools made from special while providing provide a perfect Special regulatory requirements cutting materials. In medical technology, for instance, the substitute. An important product group When machining prostheses, two aspects should be synchro- DHC HARDLINE carbide end mill is used. The uneven DHC are artificial joints. The demand for these nized perfectly. On one hand, the most economical solution with (Different Helix Cutter) geometry enables extremely smooth prostheses is high and implants are now the shortest machining time must be found. On the other, the running and precise machining of high-strength materials up a routine operation.2 However, their regulatory requirements for medical technology procedures must to 1,600 N/mm 2. processing places extremely high be in compliance. One special requirement is, for instance, that demands on tooling and processes. no residual oils or lubricants can remain on the component. It has Complex component geometry now also been requested to remove coolants altogether. This LMT Tools offers suitable tooling With a joint prosthesis, the shape and the applied forces must means that even more heat is created and that the tools are solutions for the machining of prosthetic be synchronized with high precision. The “king” is the knee joint. subjected to more strain. All this requires a holistic strategy which joints. We will show you the challenges It is the largest joint in the body and is subject to a heavy load. provides the optimal combination of standard and special tools. that need to be mastered and how However, it is not just the geometry of the joint parts, but also the LMT Tools is developing such strategies especially for the field of central solutions . machining of its surface. The side of the prosthesis which is medical technology. They enabled a manufacturer of knee joints integrated into the bone must have a rough structure to be able to reduce the machining time per joint from 45 to 30 minutes still to provide better adhesion. On the other hand, highest surface meeting all the special regulatory requirements. quality is also a factor to keep friction to a minimum. For machining, LMT Tools offers both standard solid carbide tools and special tools. The trochoid machining method has been shown to be particularly efficient, due to the circular feed motion controllers Including can use to markedly reduce machining times, while maintaining Additive manufacturing increasingly plays a part in prosthetics. the highest quality. It is used for the faster manufacturing of prototypes (Rapid Prototyping) as well as for single prostheses for individual patients. There are no long-term results for the life of prostheses made by 3D printing, but the potential is huge. However, joint prosthesis produced with additive manufacturing require a finish of the highest quality to prevent friction and premature wear. For a perfect finish for printed prostheses 1 LMT Tools is, therefore, developing machining solutions – in Source: BVMed, The market for medical technologies; the spirit of exactly yours. based on figures provided by GTAI, U.S. Commercial Service and Eurostat/Spectaris for 2017 2 In the ranking of the most frequent operations in Germany prostheses on the hip joint are number 8, on the knee joint at number 18. Source: Federal Office of Statistics/Destatis (2015) 10 11 Topic of the day: Aerospace Ascending force: a demanding challenge Florent Mathieu Head of the Reaming segment, [email protected] The “exactly yours” solution for machining this turbine component was a combination of three reamers:

1. An uncoated carbide reamer with cutting length to ream the beginning of the hole

2. An uncoated carbide reamer with a longer cutting length for semi-finishing

3. A a coated brazed reamer of the FTR series for finishing

1.

Cold air is flowing in at the front, at the back a hot high- hole for attaching the turbine blades must be precisely cut to For the pre-stage and semi-finishing stage LMT Belin used two velocity provides the thrust. In engines, the ensure that the blades fit perfectly and that the turbine is uncoated carbide reamers (figures 1 and 2), and for the finish, material is subjected to extreme conditions. To achieve a functioning properly. a coated brazed reamer of the FTR series (figure 3). This better fatigue strength, crucial aerospace drive components strategy enabled the finishing of the martensitic stainless steel are increasingly made of solid steel blocks instead of many Tool strategy for tight tolerances 1.4923 in stages until it was below the required tolerance individual parts. However, this complicates finishing as even Looking for a suitable processing strategy, the aerospace manu- limits. This solution also successfully passed several tests 2. the smallest inaccuracy may affect the entire component. facturer contacted LMT Tools. “One of the challenging issues carried out by the , including destructive was to ream the attachment holes maintaining very tight toler- material tests and microscopy analyses. This test showed that A manufacturer of low-pressure turbines had to cope with this ances and a high surface quality,” says Florent Mathieu, Head of LMT Tools offers a reliable machining strategy for demanding problem. These complex components are the final part of the Reaming segment at LMT Belin. “The required tolerance aerospace components. the aircraft engine before the high-velocity jet is released into range is an average roughness of 0.8 maximum. Several competi- free air. Thanks to modern CNC machining centers, the main tors had already failed to meet this requirement. Within three body of low-pressure turbines can now be manufactured from weeks, we developed an ‘exactly yours’ solution involving a 3. a single solid block. The workpiece is subjected to numer- multi-stage tool strategy. We combined three different reaming ous processing steps and consequently costs several thousand tools, ensuring a consistently high precision, even at tolerance Euros. The final steps are especially crucial and without extreme values of 0.3 to 0.4. The most important factor was to ensure that precision, all of the previous work would be worthless. Each drill each of the expensive workpieces had exactly the same final contour. This was achieved by a reliable machining process. And that was exactly what the customer wanted.”

12 13 Topic of the day: Aerospace Quick and reliable Dr. Matthias Lange, Premium AEROTEC (right), with Maik Kämpchen, at Premium AEROTEC LMT Tool Systems, with the component lock made from titanium for the freight door of the A350

edges on the circumference cutters as well as interior cooling with radial coolant discharge.

“A particular challenge during the manu- facture of these complicated tools was measuring the high-precision supporting chamfers which stabilize the cutting edges during titanium machining while also contributing to a low-vibration cut,” explains Peter Unruh, Head of Aerospace at LMT Tools. “LMT Fette invested in special measuring equipment for this purpose.”

This is just another example that substan- tiates LMT Tools’ claim “exactly yours”.

The demand for customer-specific HPC carbide cutters is high. The experts of Premium AEROTEC Dennis Eilers, Tool Management and Production Planning Speed and reliability are permanent, production of components with a high for micro geometries on the cutting edge (left), and Peter Schilling, Head of Tool universal requirements for precision material value,” Dr. Matthias Lange, of the tool. Quick response times and the Management (right), with Peter Unruh, tools. However, for Premium AEROTEC Core Technologies at Premium AEROTEC, reliability of our partners are the keywords Head of Aerospace at LMT Tool Systems. at their Varel location, they are of special explains. here.“ significance. “But speed and reliability have another LMT Tools meets these requirements and Premium AEROTEC is a leading supplier of civil and military for the B787 (“Dreamliner”). Current military programs “Of course, the carbide cutters we use for essential significance for us”, Lange is now the main manufacturer and supplier aircraft components as well as a partner in the major European include the Eurofighter Typhoon and the new military transporter the machining of aircraft components continues. “It concerns our requirement for of carbide cutters for Premium AEROTEC and international programs. Their core is A400M. In Germany, the plants are located in Varel, Nordenham, made of aluminum and titanium must be joint developments and permanent at Varel. The HPC (High Performance the development and manufacture of large aircraft components Bremen, and Augsburg. fast. For instance, we were able to optimization of innovative tool solutions on Cutting) tools required with a diameter of made from aluminum, titanium and carbon fiber reinforced significantly increase the material removal the one hand, but also a holistic approach, 16 mm and 25 mm are highly specialized plastics (CFRP). With around 10,000 employees at various loca- The plant at Varel employs approximately 1,500 people, of which rate for roughing and finishing of titanium i.e. taking a look at the entire process , their features are specified by tions in Germany and Romania and sales of two billion Euros, about 600 work in the machining department. Every year, roughly components. We also require maximum which includes the machine technology, Premium AEROTEC. The customer-specific Premium AEROTEC is number one in Europe in this segment. The 14,600 tons of aluminum and 420 tons of titanium are machined reliability with regard to tool life and quality setting up tools, the tool holders with features include a high number of cutting Tier 1 supplier is represented in all of the civil programs there. Around 8,000 different tools produce 13,500 tons of chips as we cannot afford interruptions to our efficient shrink chuck technology as well edges with an uneven pitch, stabilized with his products. The company also supplies major components per year. The company manufactures large parts from aluminum as measurement technology, in particular, corner radii and supporting chamfered and titanium such as aircraft frames and rotating small parts such as lock furniture from aluminum, steel and titanium.

14 15 Milling Highlights Mold design

The copy milling cutters of the twice as easy CopyMax® product family provide a long Hanjo Gissler tool life and time-saving handling. Product Manager Mold and Die making, [email protected] The long life of these tool which could be increased by a factor of four when using both cutting edges of the CopyMax®2, is based both on the innovative high- performance coating Nanomold Gold and the HQS manufacturing process (patent pending). The increased process pressure and a special mold design provide even more stable cutting edges.

Another benefit of these copy milling cutters is the easy and time-saving handling. The indexable insert can be changed within the machine without disassembling the tool shaft – in less than a minute. A specially developed clamping screw also ensures that the indexable insert can be mounted accurately, safely, and easily in the tool holder.

Transparent image of CopyMax®2

The CopyMax® product family has been is and remains a main factor The strong performance of the CopyMax® extended. The double-sided CopyMax® 2 for success. If improved performance is product family comes into its own during insert has proven its worth in mold and added to this, the potential for savings the roughing and semi-finishing of larger die making, LMT Kieninger has now increases significantly. The newly devel- molds and the removal of residual material. developed the one-sided CopyMax® 1 oped CopyMax® product family focuses Depending on the composition of the plate. New carrier tools have also been on these two factors: cost through the component, customers can either use the added. Another addition to the program manufacturing process HQS (High Quality single- or double-sided version of the CopyMax®1 indexable insert, is a cylindrical version of the steel shafts ) and maximum capability in mold CopyMax® indexable inserts and thus coated with Nanomold Gold in two different lengths and cylindrical and die making. determine the specific advantages them- screw-on cutters. The extra tools are selves. In any case, the user achieves available with internal coolant supply. maximum process reliability in terms of quality and service life.

CopyMax®2 indexable insert, also with Nanomold Gold

16 17 Milling Highlights More efficient by the dozen Maximum toughness

The roughing of high-strength materials is one of the most The efficient machining of hardened and In practice, this special geometry results demanding milling processes in mold and die making and high-strength materials places high in a marked reduction in machining time. in machine . For an optimum tool life, the cutting demands on machining tools. The users During the high-feed machining of highly tool and the inserts used must be extremely stable and want long tool life and the maximum tempered steel 1.2343, it was possible heat-resistant. At the same time, it also requires high dimen- removal rate. To meet these require- to halve the machining time compared to sional accuracy so that the roughing process gets as closely ments, the development goes to the a competitor’s tool. The long tool life of as possible to the final contour. limits of what is achievable. However, 165 minutes also contributes to reducing this does not apply to LMT Fette’s costs. The MultiEdge 2Feed mini works The well-known ACU-Jet roughing program by LMT Kieninger high-feed cutters. The new indexable very reliably and economically, even with meets all these requirements. The ACU-Jet Double6 system, in inserts markedly extend the capability large projection lengths. particular, enables a marked increase in performance. It includes of the established MultiEdge 2Feed mini. indexable inserts with six cutting edges per side, which means The indexable inserts, referred to as that the service life of the indexable inserts can be increased up A special carbide substrate, combined XDMW 090316 SR, which are made from to a factor of twelve. The exact positioning and, therefore, with a TiAlN-based high-performance the new LCHP15M cutting material, also optimal utilization of the cutting edges, is ensured by small lock- coating, easily copes with material show what they are made of when ing points on each indexable insert. They also secure the inserts hardness and strength and outperforms machining extra-hard steels up to 63 HRC against twisting – contributing to a more reliable process. comparable competitors’ products. The and permanent mold casting up to tried-and-trusted high-feed geometry 67 HRC. A high material removal rate can Double6 becomes Premium of the 9 mm small inserts for infeed be realized even on lower-performance ACU-Jet Double6 Premium The developers at LMT Kieninger were able to increase the depths up to a maximum of 1 mm with machines. The carrier tools are available in a field trial: performance of the ACU-Jet Double6 once again. The ACU-Jet a thickness of 3 mm allow for a veritable as screw-on cutters in the diameter Double6 Premium version provides a new base plate with Machine: Droop&Rein with Fidia C20 flood of chips during roughing. An range of 16 mm to 42 mm for two to six diameters of 32–42 mm (screw-on cutter) and 40–66 mm Holder: FCC R12.042AN 40-05-I-Double6 important factor in this is the slightly indexable inserts and as a shell-type (shell-type cutter). The new design makes operation even easier WSP: RNLU R1204MO, grade LCPK25M positive angle of attack of the indexable cutter version from 35 mm to 80 mm for and ensures rotation with optimum smooth running. The index- inserts. up to nine indexable inserts. The dimen- able inserts are cooled directly via the insert seat. Cutting data: sions of the indexable inserts are identical for all versions with different diameters. To complement this design, LMT Kieninger has developed Vc: 140 (175) m/min a new indexable insert with a positive rake angle and numbered n: 1,062 (1327) U/min cutting edges. For the 12 mm diameter, it is available in four fz: 0.5 (0.9) mm wear-resistant grades as well as in two different geometries: Vf: 2,654 (5971) mm/min RNLU-R for roughing and/or RNLU-M for medium roughing. ap: 1.2 mm ae: 26 mm Q: 83 (186) cm³/min

The ACU-Jet Double6 Premium provides even easier operation and optimal smooth running.

The MultiEdge 2Feed mini mills in maximum hardness.

18 19 Milling Highlights

The easy cutting face-milling cutters can be used for many different applications. Many faces, one mission With the different cutting materials and geometries of the indexable inserts, users can efficiently machine a wide range of Korvin Michalak materials from steel and stainless steel to Product Manager Indexable Insert Cutters, highly heat-resistant steel and titanium [email protected] alloys. With the new tool system, individual

requirements for high infeed depths ap to 6 mm (four cutting edges) or a high

number of eight cutting edges (for ap max. = 3,5 mm) can be selected. Even unfavor- able machining conditions can be over- come.

The new MultiFace face mill cutters are available in standard diameters of 50 to 160 mm. For versions with normal pitch and fine pitch, four to 16 indexable inserts are used. With four or eight cutting edges per indexable insert, customers can always select the right system for their application. This great selection meets the many different requirements of our customers and, therefore, embodies the motto “exactly yours” very well. 0

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For economical roughing operations, The indexable inserts of the MultiFace In the practical application below, Material removal rate [cm3/min] only one factor is crucial – the maximum H45 PRO4 are set up high-positive and machining has been taken to a new level. material removal rate possible. For have four cutting edges. The MultiFace During the face milling operation on a modern machining centers, this doesn’t P45 PRO8 has positive indexable inserts copper block, different requirements were 800 The lower machining forces of the just require innovative milling tools, with eight cutting edges each. This tooling clearly exceeded. Due to the low power MultiFace H45 PRO4 milling systems but also requires a selection of cutting geometry markedly reduces the spindle consumption of the high-positive tool 676 produce a large amount of chips. tools for modern materials. These load. Even on low-power machines, it is version, it was possible to increase the requirements are easily met by the possible to achieve large material removal diameter of the tool used from 100 mm to 600 new face milling system MultiFace H45 rates. This saves manufacturing time and 160 mm in order to increase the radial

PRO4 and MultiFace P45 PRO8 by machine costs as well as resources. infeed ae to 102 mm from 48 mm. Thanks LMT Fette. to optimized cutting values, the material removal rate could be more than doubled 400 to 676 cm³/min. The service life per cutting edge also increased from 18 hours to 339 24 hours, reducing wear even further. 200

0 Competitor MultiFace 20 H45 PRO4 21

Threading Highlights Gear Cutting Highlights Quality comes Combines from within Andreas Möller cost effectiveness André Bollow Product Manager Threading, Product Manager Gear Cutting, [email protected] and precision [email protected]

The efficient manufacture of female threads is the result of The engineering experts at LMT Fette have created a compre- intensive tool research, constantly providing new challenges hensive product portfolio for the various performance and for the creativity of the engineering experts. LMT Fette quality requirements of gear cutting for vehicle transmissions Connecting rod application presented the first generation of HPF forming taps years through to drives in wind turbines. 100 years of experience, in ago and, in the meantime, has established itself in the market combination with the latest , results with its unique selling point of a modular design. High in constant innovative solutions being generated to reduce the Performance Forming (HPF) combines the benefits of cost per part even further. the wear resistance of a carbide threaded head with the toughness of a steel shaft, ensuring a new performance This is how the new UNIFY came to be. It also strengthens the standard in terms of quality and efficiency. area of application of the proven gear hob family CarbideLine-I (I = Indexable) in the module range from 6 to 12 and is the HPF Max, the improved forming tap of LMT Tools, unlocks a preferred choice when high performance and high quality are a new dimension of performance. In addition to the modular design, requirement for the machining of gears. The new design of four additional noteworthy design features make a significant the UNIFY has created a single-part, which is a compact, very contribution: robust base plate which works with extreme precision due to the minimum number of interfaces. This construction enables the use • the new fine-grain carbide substrate LCP25G of indexable inserts for hob cutting on diameters from 150 mm. • the new TiCN coating It can be used on smaller machines with fewer limitations due to • the optimized form geometry collisions and advantages with regard to processing time. In the The new indexable insert gear hob, UNIFY, • the superior performance which has been visualized through practical application at Eickhoff Maschinenfabrik in Bochum, has a compact and robust base plate. the new look of the Premium shaft The modular forming tap HPF Max scores Germany, the new gear hob with indexable inserts (210 mm with its high tool life. diameter, Zeff: 12, R1) easily passed the test. It was used for the This superior performance can, for instance, be achieved during machining of a module 9 skew gear made from the material 18 the manufacturing of blind hole threads MF 12 x 1.5 in connecting CrNiMo 7–6 with 88 teeth and a gear width of 220 mm. rods from the C70 material. In this application, the forming speed Tool life [number of threads] was vc = 20 m/min. It was cooled by emulsion. The new modular The UNIFY, which had been customized for this application, used forming tap, HPF Max, achieved a tool life of 3,200 threads. a protuberance plate with 4 cutting edges to achieve a gear Compared to a competitor’s single-part solid carbide forming tap, 4,000 quality of 9 with its first attempt. The responsible at Eickhoff were this result means an increase of 166 percent. very satisfied with the result. “We are particularly happy with the 3,200 smooth running and the very even surface of the component.” said Oliver Richter, who is responsible for technology at Eickhoff. 3,000 He was also impressed with the capability of the tool, “The gear hob has delivered a very strong result, we are very happy with the machining time.” 2,000 The UNIFY combines precision and efficiency and has proven to 1,200 be a new, strong partner for series production in the medium module range. 1,000

Practical application of the UNIFY at 0 Eickhoff Maschinenfabrik in Bochum Competitor’s HPF Max 22 solid carbide 23 Rolling Highlights Advanced Tooling Highlights Rolling Actuation promotes with precision David Szillat precision Head of the Rolling segment. [email protected]

On its own, thread rolling is already the How did the market react to the Highest precision for large quantities is and then the actual value of the diameter most efficient method for manufacturing new offer? also required within the automotive is forwarded to the machine control. The male threads. Extremely short manu- We had already introduced the concept industry. For instance, when machining measurement computer then compares facturing times, high thread strength last year. In the meantime, the first crankshaft bearing bores and cylinder the actual value with the required toler- and press-finished flanks are some of customer solutions have been imple- bores, extremes meet. Efficiency, ances. The cutting edges are then the significant characteristics of this mented. Customers who are using rolling smooth running and low-wear operation readjusted to the new diameter in a fully process. are now able to increase both the reliability of the entire engine depend on the automated process. The result is a of the processes and the quantity of quality and dimensional accuracy of this significant increase in workpiece quality With the new CTline concept (Custom- produced parts, reducing the cost per part central bores. Their high-precision and cost savings. ized Tangential rolling heads), there even further. Other new developments, finishing operation is therefore carried is now an additional top performer for such as our individual chip protection out using line boring bars as their design. The time required for readjusting the the manufacture of threads. David cover, also contribute to higher reliability. The holder systems and inserts can be cutting edges within the machine could be Szillat, Head of the Rolling segment at individually designed and adapted to any adjusted by 70 percent. This means that LMT Tools, provides an insight. Who benefits from this increased engine type. not only is the tool highly efficient, it also efficiency? meets the main requirements of a Smart Mr. Szillat, what are the particular char- Anybody who wants to produce precise These line boring bars by LMT Kieninger Factory with its actuating capabilities. acteristics of the new concept? male threads quickly, preferably in series define a completely new tool generation. The new aspect is that we are not only production, and anybody who wants to What is new is that these tools are optimizing thread rolling as such, but increase their productivity even more. additionally equipped with an internal tie aligning our performance stronger with the rod to enable the automatic readjustment entire process – and taking into consid- of the cutting blades to compensate the eration the customer-specific production wear of cutting edges. This means that the conditions. This includes – as before – time-consuming manual readjustment of the components. But we are now focus- each individual cutting edge is no longer ing on the customer’s machine, in par- necessary. Circularity and coaxiality show ticular on the individual connection of the a very high degree of precision and the rolling head using adapted holders surface of each bore is of the highest and on the specific coolant supply. To find quality. Normally such an actuating solutions even more quickly and to opti- process goes through a measuring control mize functions, we now also include the loop. First, the bearing bore is measured additive manufacturing method 3D printing. This makes each rolling head a unique piece, exactly made to measure The actuating line boring bar and individually designed for each is perfect for the finishing of crankshaft customer. bearing seats.

This is what a customized upper hinge for a tangential rolling head from a 3D printer can look like according to a design study – with chip protection and targeted coolant supply. 24 25 Coating Highlights LMT Tools Progress News

Dr. Philipp Immich through research New production plant in China Head of R&D Lubricants and Coating, China increasingly relies on high-value technologies. LMT Group [email protected] will continue to show a strong commitment in this growing Tool coatings play a major part in metal “For example, during hobbing, we not market environment. The group will, therefore, build a new plant cutting manufacturing technology today. only managed to carry out roughing in Nanjing on a site of more than 50,000 square meters in 2018. Coatings significantly contribute to and finishing operations with the same “With LMT Tools we are one of the few high-quality providers the realization of cutting speeds of up to tool, but also with a single coating,” in China, particularly in the field of mold-specific tools,” explains 600 m/min, for instance, during hob explains Dr. Philipp Immich, Head of R & D Erwin Geissler, CEO of LMT Tools China. “Together, with other cutting. They enable an increase in tool Lubricants and Coatings at LMT Fette. locations, we can map the entire portfolio of our segments and life of up to 500 percent, for example, “This requires the layer to cope with both thanks to our new machinery, our local value creation is also during tapping. By dramatically short- large and small head chip thicknesses. growing.” ening machining times, they also Together with our SpeedCore gear hobs, contribute to a more efficient use of the our current AI7 coating enables a machines, reducing costs on a large further increase in cutting speed of up scale. to 30 percent.”

However, coating requires expert knowl- edge and experience in the use of tools. 60 million Euros of new investment In the coating centers of LMT Fette LMT Tools continues its global growth program. In addition to and LMT Kieninger, experts give their all to Effect of new coating systems on the extending the Centers of Competence, the focus will also develop new coating systems, tailored cutting speed during hob cutting be on extending the capacity for the reconditioning and coating to the respective application and helping Tool life: 2,000 manufactured gears of tools in 2017 and 2018. The total investment volume is to exploit the maximum capacity of tools Aborting criterion: VBmax, permitted: 120 µm anticipated to be 60 million Euros. LMT Group will also build a during milling, hob cutting and threading. new production plant in China. The expansion of LMT Group's 400 Tool: global network of training facilities will also strengthen the global Coating: various Following the motto “exactly yours”, the presence of LMT Tools. Following the example of the LMT Group Module: 2.05 mm experts promise their customers to provide 350 Diameter: Academy in Schwarzenbek, the company has now opened exactly the solutions that will actually 80 mm two further academies: 2015 in Nanjing, China, and 2016 in Goa, benefit them. This promise also includes Cutting edge length: India. special high performance coatings which 300 150 mm stand out against standard solutions Number of gashes: 18 and, at the same time, feature the latest Number of gears: 3 250 tool research innovations. Material data: Material: 20MnCr5 200 Pressure angle: 17.1° The new catalogs Helix angle: “Tools and Knowledge” are out: LMT Tools Fräsen LMT Tools Alésage 26.48° Werkzeuge und Wissen Outils et compétences 150 LMT Tools Milling LMT Tools Reaming Outer diameter Tools and Knowledge Tools and Knowledge To find the best solutions for machining questions you need the 106.5 mm right tool as well as the matching know-how. The catalog series Gear width: 19.15 mm “Tools and Knowledge” combines the two aspects well. It bundles Cutting speed [m/min] 100 the entire tool expertise and provides valuable tips for practical Technology data: applications. 50 hcu: 0.204 mm LMT Tools Fräsen Werkzeuge Fräsen und Wissen Tools LMT and Knowledge Tools Milling Tools LMT Dry cut: LMT Tools Alésage Outils et compétences LMT Tools Reaming Tools and Knowledge Find out about the latest tool innovations and the associated www.lmt-tools.com www.lmt-tools.com Ganging know-how with our new catalogs: 0 “LMT Tools Milling – Tools and Knowledge” and PM-HSS SpeedCore SpeedCore “LMT Tools Reaming – Tools and Knowledge”. coating: AI6 coating: coating: www.lmt-tools.de/en/downloads (AICrN) AI6 AI7 (AICrN) (ml-AICrXN) 26 EN 0373

A perfectly normal technology enthusiast at LMT Group

Women are successful in technologic industries. We are Laura Peters with Artur Tovmasian happy to be able to train more and more women in technical and Waldemar Lizenberger, occupations who are enthusiastic about . Women Apprentices at Schwarzenbek in leadership roles at LMT Group is perfectly normal for us. Find out more about us at www.lmt-group.de/en/careers

Efficiency through innovation.

LMT-GRO-17-5002_Anz_Technikfreak_EN_200x137.indd 1 07.08.17 16:28

LMT Tool Systems GmbH & Co. KG Heidenheimer Strasse 84 73447 Oberkochen, Germany Phone +49 7364 9579-0 [email protected] LMT Belin France S.A.S. LMT Fette Werkzeugtechnik Lieu dit „Les Cizes“ GmbH & Co. KG www.lmt-tools.com 01590 Lavancia, France Grabauer Strasse 24 Phone +33 474 758989 21493 Schwarzenbek, Germany [email protected] Phone +49 4151 12-0 www.lmt-belin.com [email protected] www.lmt-fette.com

LMT Kieninger GmbH LMT Onsrud LP Vogesenstraße 23 1081 S. Northpoint Blvd. 77933 Lahr, Germany Waukegan, IL 60085, USA Phone +49 7821 943-0 Phone +1 847 3621560 [email protected] [email protected] www.lmt-kieninger.com www.onsrud.com