stories on hard material matters - Ceratizit S.A.

01/08
<strong>stories</strong> on hard material matters
Titanium machining
Substrate, geometry and coating
expertise - a symbiosis Titanium cannot resist.

MaxiMill systems
Space age materials cut easy.
Aerospace, Power generating ...
The No.1 solution for Titanium, Stainless
and High tensile steels.
Double Your Productivity!
Metal Removal Rates 200% Higher
CERATIZIT USA Inc. 5369 Rt. 982 North 15650-0272 Latrobe, Pennsylvania Tel:+1 803 736 1900 E-Mail: info.usa@ceratizit.com

Today, CERATIZIT is already the world-market leader for
carbide products in wood and stone machining as well
as Europe‘s largest supplier for industrial wear parts. The
group is also gaining strength in the USA where we are
catching up in the ranking.
Furthermore, CERATIZIT counts on the segments where -
thanks to our expertise – we can achieve the best
customer benefit and growth opportunities. In the
coming years CERATIZIT will focus on Cutting Tools and
consistently implement their multi-channel strategy.
They will concentrate on niches and develop exclusive
solutions for the automotive, engineering, aerospace
and oilfield sectors.
We want to strive for continuous organic growth above
average worldwide. Ever since its foundation CERATIZIT
has grown notably quicker than the market. This is how
we want to continue, amongst others through targeted
acquisitions. In this context new companies have to
adapt to the CERATIZIT group strategically, culturally and
also financially.
With a turnover of approx. 600 million euros (850 million
US-dollars) the carbide producer ranks among the TOP
5 worldwide. We are now striving for a turnover of one
billion euros by 2012. In order to reach this ambitious goal
we have several levers that we can activate efficiently.
Pressing ahead with internationalization
CERATIZIT has a strong position in Central and Eastern
Europe, thus we were able to benefit extraordinarily from
the economic growth in Eastern Europe and will be further
extending our success. CERATIZIT is excellently positioned
in the NAFTA area, which is still the strategically most
important market in the world. We have companies in
the USA and in Mexico where we have been gaining
market shares for years. After the acquisition of Newcomer
Products last year CERATIZIT has become a ‘household
name’ also in the American Cutting Tool sector.
Latin America for us is an independent market with
high potential. For years the company has achieved
A WORD
FROM THE BOARD
A WORD FROM THE BOARD
double-digit growth rates, and after Eastern Europe and
East Asia, Latin America will remain the growth region
where we will be investing most intensively. East Asia is
at the top of our agenda, as we have companies in the
three most important markets, China, Japan and India
which contribute in a higher-than-average way to the
group’s growth. We will certainly press ahead with our
efforts in the Asian markets.
“We consistently optimize our processes”
Rationalization is always a topic as the cost pressure from
competitors never ceases. This does not however mean
that we are trying to attain the cost structure of our Asian
- namely our Chinese - competitors. And we will also not
be moving our entire production to low-wage countries
as we obviously want to maintain our high standard with
regard to quality, products and services and above all
our customer proximity. This however does not rule out
production being transferred in single cases.
“We prefer to be the number 1 in selected segments than the
number 3 overall”, says Board member Wolter.
In the framework of our current project, FOCUS FUTURE,
our aim is to interlock production and sales, also geographically,
in such a way that the customer‘s requests
are fulfilled as quickly and efficiently as possible. At the
moment this project basically concerns the West
European production sites. But the more we grow in Asia
and Latin America, the more we will extend our production
in these regions to maintain customer proximity.
We want to optimize all the processes which are necessary
to fulfill the customer’s requests. For this purpose we
have to continuously increase efficiency in all areas, i.e.
research & development, acquisition, sales, production
and logistics. CERATIZIT and our employees have already
attained a lead over competitors.
Thierry Wolter
Member of the Executive Board
thierry.wolter@ceratizit.com
03

CONTENTS
03
06
07
08/09
10
11
12/15
16/17
18/19
20
21
22/23
24/25
26/27
28/29
30/31
32/33
34
35
36/37
38/39
41
42/43
A word from the Board
Thierry Wolter
Brovedani SPA / Italy
MaxiClick
Plansee Seminar 2009
- from 25 to 29 May 2009 in Reutte, Austria
Newcomer Products
A CERATIZIT brand
GTP
Part of Plansee Group
MAC cooling set
Dry aluminum wheel machining
Audi Hungaria
Crankshaft machining
Leicht und Müller
Stamping industry
Åkers / Sweden
Roll Machining
MaxiMill HEC
High Efficiency Cutting
MaxiMill HFC
High Feed Cutting
Titanium Machining
CTC5240
Rado
Carbide watch cases
Hilti
Drill manufacturer
HPC 12
High Performance Cutting
BGH Edelstahl
Bar peeling vs. turning
Hunting Oilfield Services
Netherlands
Coated CBN
World innovation from CERATIZIT
OvalFlex
The oval all-rounder for aluminum wheels
Austria Alu-Guss
Rim production with CERATIZIT tools
Titan Zrinski Tehnologija
- has found the right tooling partner
Water cutting technology
Divisions:
Cutting tools, wear parts
1
2
3
1
2
imp:act 01/08

3
IMPRESSUM
IMPRESSUM
imp:act, <strong>stories</strong> on hard material matters
Customer magazine from the CERATIZIT
Group
Published twice a year
Publisher:
CERATIZIT S.A.
Route de Holzem, B.P. 51
L-8201 Mamer
Tel.: +352 312 085-1
Fax: +352 311 911
E-mail: info@ceratizit.com
www.ceratizit.com
Responsible editor:
Filip Miermans
PR and group communication
Tel: +43 (5672) 200-2127
Fax: +43 (5672) 200-526
E-mail: fi lip.miermans@ceratizit.com
Design development:
Agentur Singer, Lechaschau,
Austria (www.agentur-singer.at)
Printed by:
RWF Frömelt-Hechenleitner
Werbegesellschaft m.b.H.
Volders, Austria
We reserve the right to make technical
changes for improvement of the product.

06
BROVEDANI SPA, ITALy
Brovedani SpA from Italy has been a customer of
CERATIZIT Italia SpA for years and now applies
MaxiClick from CERATIZIT. With the parting and
grooving tool MaxiClick Brovedani machines pump
filters for the automotive sector. Brovedani
produces 150 million components per year: injection valves,
plunger adjustment systems and steerage systems for
the automotive and motorcycle industry. Brovedani
was founded in 1947 in Pordenone (Italy); today the
company has 500 employees.
“We were looking for a new solution which was
supposed to enable us to change the tool rapidly and
easily,” says Denis Pistor, technical tool manager at
Brovedani. The parts which have to be machined require
a consistently high quality level which had to be
maintained or even improved. In this context productivity
was also to be enhanced through time saving. When
parting and grooving pump filters we applied MaxiClick
MC 10 from CERATIZIT and a coolant on our material
42CrMo4 with a hardness of 300 Hb. Compared to the
parting and grooving systems applied beforehand,
a gratifying cost saving and a 40% production
increase resulted. We frequently part off steel bars,
and as MaxiClick is a particularly narrow insert a great
deal of material can be saved.“
MaxiClick – parting and grooving tool with highly
productive cutting operations
Michele Carraro, cutting tool sales manager of
CERATIZIT Italia SpA, can only confirm the experiences
of his customer: “The first tests with the CERATIZIT parting
and grooving system has already created considerable
interest. Its innovative tool design gives a simple method
of breaking off the worn-out cutting edge and replacing it
quickly thus reducing unproductive downtime.”
The parting and grooving tool with the break-off cutting
edges consists of a tool shank with a longitudinal lateral
groove where up to five cutting edges are placed one
after the other. The first cutting edge can simply be
broken off after having worn out, so room is made
for the following cutting edge. After a very short time
the tool can be used applying the new cutting edge.
Carraro: “Like the carpet cutting knife for professionals
from the DIy.”
The parting and grooving system consists of two different
tool holders or tool shank types and inserts with cutting
imp:act 01/08
CERATIZIT customer story:
Brovedani machines with MaxiClick
widths between 0.04 and 0.1". The total length of the
cutting insert is around 2.36". Depending on the insert and
the tool holder MaxiClick makes cutting depths up to 0.4"
possible.
The MaxiClick tooling system is designed for optimum swarf
control and for optimized combinations between material
and coating for a wide range of applications.
MaxiClick in operation at Brovedani SpA in Italy.
MaxiClick at the CERATIZIT customer Brovedani in Italy. The first cutting
edge can simply be broken off after having worn out, so room is made for
the following cutting edge.

PLANSEE organizes the
17 th PLANSEE Seminar
from 25 to 29 May 2009 in Reutte, Austria
Scope of the Seminar
The presentations at the 17th Plansee Seminar will cover
all market segments where products made from high
performance P/M materials (metals, composites and
hard materials) are currently playing an important role,
or where they offer promising alternatives to current
material solutions.
Message from the Secretary
The 17th Plansee Seminar on Powder Metallurgical High
Performance Materials will take place at the headquarters
of the Plansee Group in Reutte, Austria from
May 25 – 29, 2009. It is my pleasure to invite the worldwide
community involved with powder metals and hard
materials to participate in this event. A special invitation
is extended to students and young scientists engaged
in the field of powder metallurgy. Since we gathered
at the previous Plansee Seminar, the economic growth
particularly in Asia has strongly increased the global
demand for raw materials and hence the costs for metal
powders.
PLANSEE SEMINAR 2009
At the same time, responsibility for our environment
impels us to critically review the amount of energy
consumed in the manufacture of P/M products.
This poses the challenge of further optimizing the
overall material efficiency, e.g. by near-net-shape
forming and by recycling, and of introducing novel, more
energy-efficient processes, in particular for sintering.
On the other hand, innovative P/M materials will continue
to play a key role in increasing the efficiency of all
kinds of machinery, for energy conversion, for transportation
etc. Developments in all these directions are well on
the way. In this context the Plansee Seminar will once
again serve as a global forum to de fine the current
status of the science and technology of powder metals
and hard materials. It will also provide a guideline for the
direction of the developments that we should embark on.
Peter Rödhammer
Secretary of the Plansee Seminar
07

08
NEWCOMER PRODUCTS, USA
CERATIZIT acquires
Newcomer Products, Inc.
Newcomer Products in Latrobe/Pennsylvania
CERATIZIT of Mamer, Luxembourg acquires Newcomer
Products, Inc, a privately owned company headquartered
in Latrobe, Pennsylvania. The agreement was signed on
July 10th, 2007.
“The Newcomer acquisition meets our objective for
sustainable global growth through expansion in the
NAFTA countries and Asia,” comments CERATIZIT
Spokesman Jacques Lanners. Newcomer is the third site of
CERATIZIT in the United States.
Newcomer Products, Inc., a household name in the US
carbide industry
Privately owned US company Newcomer Products
is specialized in the manufacturing and finishing of
tungsten carbide products for metal cutting and wear
applications. From water-based spray dried powders
to sinter-hip technology, Newcomer Products is on
Nate Parker and Thierry Wolter after signing the agreement. Spokesman Jacques Lanners.
imp:act 01/08
the leading edge of carbide enhancements and
supplies major US metalworking industries.
The company was founded in 1945. Today Newcomer
Products employs 130 people and realized sales of more
than 20 million dollars in 2006. The company’s head-
quarters are in Latrobe, Pennsylvania.
Says Nate K. Parker Jr., Chairman of Newcomer Products:
“We were looking for a partner with strong technolo-
gical support and both a global view and strong roots in
the US. Clearly, CERATIZIT is one of the rising stars in the
business and they wanted to build up their presence in
the US. CERATIZIT is a perfect fit and we are happy to be
part of their team“.

Robert Eicher
Manager
customer service center
robert.eicher@ceratizitcom
Carrie Henry
Customer service center
inside sales
carrie.henry@ceratizitcom
INTRODUCTION NEWCOMER
CERATIZIT USA
Newcomer Products - a CERATIZIT Brand
P.O. Box 272, Latrobe, PA 15650
Phone: (724) 694-8100/800-45-6880
Fax: (724) 694-8620/800-544-5009
Customer Service Center Mr. Robert Eicher
E-mail: robert.eicher@ceratizit.com
Ray Benedict
Corporate
accounts manager
ray.benedict@ceratizit.com
Rob Lexa
Sales manager endusers
rob.lexa@ceratizitcom
09

10
GTP PART OF PLANSEE GROUP
US powder expert GTP
is now part of Plansee Group
Effective 1 August 2008, Plansee Group has acquired
the business unit Global Tungsten & Powders (GTP) from
Osram. The purchase agreement had already been
signed on 22 April 2008.
GTP is a leading supplier of powders, semi-finished
products and components made from tungsten, molybde-
num and phosphor. Says Michael Schwarzkopf, chairman
of the Plansee Group executive board: “With GTP we will
ensure our long-term supply of tungsten raw materials.
And we will also strengthen our position in the refractory
metals market in North America.”
GTP used to be part of the lighting manufacturer Osram
for many years. Its expertise in processing tungsten ore
concentrate and recycling of hard materials scrap has
enabled the company to become the leading supplier
of tungsten powders in North America. Its product range
additionally includes molybdenum powders and semi-
finished products, as well as other powders that are rele-
vant to the Plansee Group’s markets. GTP’s main
customers are from the aerospace, automotive, coating,
electronics, energy and lighting industries.
GTP site in Towanda, Pennsylvania.
imp:act 01/08
GTP has production sites in Towanda, Pennsylvania, and
Bruntál, Czech Republic, and employs 1,050 people. In
the last fiscal year, it recorded sales of approximately 280
million euros (around 400 million US-dollars). To meet the
Group’s increasing requirements for tungsten powders,
the Group plans to expand the Towanda site.
GTP will become the Plansee Group’s fourth division.
“GTP has performed well in the last couple of years,” says
Schwarzkopf. “We believe in the management team, and
have no plans to make any significant changes to the
product or customer portfolio.”
With the acquisition of GTP, the Plansee Group meets
its regional sales target – 50 per cent in Europe and 25
per cent each in America and Asia. The Group now
employs more than 10,000 people worldwide, 2,000 each
in the US and Austria.

World innovation: machining of
aluminum wheels now
without coolant
Benefit from savings with the new MAC cooling set from CERATIZIT.
One of the special fields of the carbide expert
CERATIZIT is aluminum wheel machining. The recently
developed MAC cooling set now allows the complete dry
machining of wheels without refitting machines. In this way
CERATIZIT once again is able to support their customers in the
automotive industry when it comes to the decisive topic
of cost reduction.
Conventional cooling in the field of aluminum wheel
machining through cooling lubricants is cost intensive.
Both the recycling of the chips and the coolant causes
considerable costs. While machining a wheel between
four and six kilos of swarf are produced. The recycling
costs are about 15 cents per pound or $ 1.5 per wheel. For
tens of thousands of aluminum rims where dry machining
is applied instead of wet machining attractive saving is
realized very quickly. With the latest world innovation
MAC from CERATIZIT, aluminum rim producers can save
money, optimize their profit and distinguish themselves
from competitors.
Ingenious: MAC cooling unit cools utilizing the Joule-
Thomson effect
“There were already various external air cooling systems
available in the market, however, their effect was satis-
factory to a limited degree. The nozzle was too far away
from the tool, too much cold air was lost,” explains
Michael Steiner in charge of the development of the new
MAC cooling set at the CERATIZIT development department.
With MAC the CERATIZIT research department has solved
this problem. The cooling unit is directly integrated into the
CERATIZIT tool. The compressed air from the machine goes
through the tool into the MAC unit and is then cooled to
minus temperatures through a physical effect known as
Joule-Thomson effect. Then it immediately hits the insert
and the work piece.
This causes the air to be divided into a warm and a cold
stream (depending on the setting). The cold air exits on
the front of the insert through the lateral holes on the
tool. The air temperature on the cutting edge is then in
subzero range and efficiently cools both work piece and tool.
About 6 bar and 100 gals./min capacity are the prerequisite.
MAC
The cold air reduces the temperature of the swarf and
enabling the tool to decrease and in a lot of cases ideally
avoids the tendency of adhesion of aluminum. The
cooling intensity depends on the quantity of air supplied,
its entrance temperature, the quality of the air and the
tool settings of MAC.
The CERATIZIT program for dry machining
Currently the following grades are available for dry
machining of aluminum wheels:
• CTP4115 (PVD –TiAlN lubricating layer; K10)
• CTD4110 (medium fine diamond grains; DP-K01)
CTP4115 is a tried and tested PVD coating with good low
friction properties. Its advantages can mainly be seen
when machining aluminum alloys with low silicon content
(Si ≤ 3 %) in combination with strong built-up edge.
In grade CTD4110, PCD (polycrystalline diamond) being
an extremely hard cutting material is characterised by
high abrasion resistance and long service life. This grade
is particularly suitable for aluminum alloys with increased
silicon content (Si ≥ 12 %), for polish turning of mirror faces
and the machining of high-quality wheels and components
in aluminum.
With the world innovation MAC from CERATIZIT aluminum rim
manufacturers can save a lot of money as they can refuse cost-intensive
wet machining.
11

12
CRANKSHAFT MACHINING AT AUDI HUNGARIA
Crankshaft machining with
tailor-made inserts from CERATIZIT
AUDI HUNGARIA MOTOR Kft. in Györ, Hungary, has 5,500
employees. Here the engines for the brands of the Volkswagen
group, Audi, VW, Skoda and Seat are manu-
factured. In Györ the Audi TT Coupé and Roadster is
built, and the Audi A3 Cabriolets will be built there in the
future. In 2006 more than 23,500 vehicles and close to two
million engines left the plant. This makes Audi Hungaria the
second biggest exporter in Hungary. For the machining of
crankshafts Audi Hungaria counts on the technology and
experience of the carbide expert CERATIZIT.
Audi is synonymous with optimum technical performance
and the logo with the four rings. In a few words: Audi ranks
as one of the top firms in the automotive world. It therefore
makes sense to purchase products at CERATIZIT, the techno-
logical leader in the field of carbide for wear parts and
cutting tools.
Crankshaft machining at Audi
Györ is situated 30 miles from the Austrian border, in
Hungary, and numbers 130,000 inhabitants. Since 1994
Audi Hungaria Motor Kft has been located at the
periphery of the town. Audi selected this site for various
reasons: the logistic connection is very good, within a
radius of 35 miles there are competitive subcontractors,
a hall with a surface of 25 acres. already existed, and a
lot of people in this area speak German very well Further-
more the technical University of Györ ensures that
well-trained engineers and experts are available.
Crankshafts are exposed to enormous forces; their production
requires maximum precision
Zoltán Szathmári is in charge of production planning and
tool technology in engine production at Audi Hungaria
Motor Kft. He works closely together with the CERATIZIT
representatives and development specialists. His most
important contact on site is Barnabás Deri, the sales
manager of CERATIZIT Hungaria.
Szathmári leads us through the impressive production
department: high, luminous halls with three extremely
long and up-to-the-minute production lines, which are
in addition fully automated. At Audi in Hungary it is very
clean and one is immediately aware that the employees are
proud to work here. In crankshaft machining Audi
Hungaria relies on seven different types of inserts from
CERATIZIT: special solutions CERATIZIT developed together
with the machine manufacturer GFM. Maximum precision
imp:act 01/08
is required. Zoltán Szathmári explains: “The crankshaft
is an essential component of the engine. It converts
the linear movement into a rotational movement. The
component is exposed to enormous forces. We
manufacture six different crankshafts. The crankshafts are
supplied in forged condition. Before machining, a
crankshaft for the 3.0 TDI engine weighs 57 Ibs, after
machining it still weighs as much as 40 Ibs.“
An Audi employee dismantling a planetary milling cutter. After around 250
crankshafts the inserts in the milling cutter have to be indexed.
Before machining a crankshaft for the 3.0 TDI engine weighs 57 Ibs,
after machining it still weighs as much as 40 Ibs.

Three highly modern completely automated production lines in the huge 25 acres hall.
Mr. Szathmári, what is important in the machining of
crankshafts?
Szathmári: “Two thirds of production relate to the 3.0
TDI engine. The crankshafts for this engine are made of
42CrMoS4. Rough machining of this crankshaft represents
a difficult task as it consists of a high-tensile material
at the limit to soft machining. The hard forging skin
virtually ‘eats away’ the tool.”
What does that mean for the tools?
Szathmári: “The blank crankshaft is irregular and shows
varying properties and the surface is not homogeneous.
This means hard and irregular strain on the insert.”
How long does an insert last?
Szathmári:“When rough machining (rough milling of
main bearing and webs) the inserts are mounted on a
KURBELWELLENBEARBEITUNG AT AUDI HUNGARy
Interview with Zoltán Szathmári, production planning and
tooling technology at Audi Hungaria
planetary milling cutter or side and face milling cutter.
After around 250 crankshafts the inserts in the milling
cutter have to be indexed.”
How do you assess the relationship with CERATIZIT?
Szathmári: “We have been working together with
CERATIZIT for four years and maintain a very open relationship,
there are no secrets. For every new development
we are informed precisely about what has been
improved. CERATIZIT is in a continuous optimization
process and is aware that coming to a standstill is
dangerous, because the pressure is high: every year we
invite tenders for the inserts, every year there are new
test procedures and CERATIZIT has to assert itself. We
have been very successful for four years.”
13

14
CRANKSHAFT MACHINING AT AUDI HUNGARIA
Interview with László Janó,
product segment V6,
mechanical production
department at Audi Hungaria
Mr. Janó, how long does the machining of a crankshaft
take?
Janó: “There are several ways of looking at this. you
could say that at the end of the production line a
finished crankshaft comes out every 49 seconds. This is
the cycle time of the line. Including the buffers (per line
there are 5,700 cranks in the buffers) the flow time for
1,400 parts per day amounts to around six days.”
How important is the role of the tools in this production
line?
Janó: “Extremely important. This line is very complex and
flexible. The investment for such a line, for instance, is
three times as high as for a line for the production of
cylinder heads. For such a complex machining method
process security has to be very good. In the automated
machining chain tool life has to be consistently high.
65% of the costs are tooling costs. The tools also play a
very important role.“
What is the proportion of non conforming material?
Janó: “The tolerances for a crankshaft are very close.
The entire line is designed for this and is continuously
optimized. Quality control is also very intensive. For the
3.0 TDI engine a 100% rupture test is carried out. For me
the quality of the final product is important, not so much
the share of non conforming material. In the last four
Patrick Zobl, product manager at CERATIZIT,
describes crankshaft machining in detail
Technique for crankshaft machining
• High cutting speeds (up to 850 ft/min)
• Planetary milling cutters with diameters ranging from
13.4‘‘ to 28.8‘‘
• Dry machining leading to high temperature stress on
the cutting material.
• High number of teeth of the planetary milling cutters
(40 up to 200 teeth)
• Main bearing and webs are machined at the same
time with two planetary milling cutters
• Due to the length and the relatively small diameter of
the crankshaft machining stability is low
imp:act 01/08
László Janó, product segment V6 with a finished Audi crankshaft.
years only two crankshafts have been returned to us; this
was due to faulty material, not to faulty machining.“
What can a crankshaft withstand?
Janó: “I don‘t want to give numbers, but the basic rule
is that the crankshaft has to withstand three times as
much as the engine.“
Requirements with regard to the CERATIZIT inserts
• High resistance to thermal shock
• Consistent quality of the cutting material providing
process security at the customer
• Long tool life, therefore low tool changing costs
• Smooth surface thanks to lower frictional heat
and wear
Materials used in crankshafts
• Cast iron materials for engines when subject to
reduced stress in the engine
• Alloyed steel (Cr, Ni, Mo) with high fatigue strength in
engines which are subject to higher stress or to reduce
weight

CRANKSHAFT MACHINING AT AUDI HUNGARIA
AUDI HUNGARIA MOTOR in Györ, Hungary: in 2006 alone more than 23,500 vehicles and close to two million engines left the plant.
Basic characteristics of CERATIZIT inserts
• Geometry of the insert is mainly defined by the profile
of the crankshaft
• CERATIZIT chooses the insert to be applied as well as
the geometry of the cutting edge
Steps in the production of a crankshaft
a. Preparation
1. Cutting and centering
2. Internal and external profile milling of the pin of the
bearing and connection rod bearing pin
3. Turning of the main bearing pins and the end parts
4. Deburring
5. Solid carbide deep hole drilling
b. Hardening (induction hardening)
c. Finishing
1. Hard turning
2. Threading
3. Chain wheel broaching
4. CBN grinding
5. Fluorescent rupture test
6. Dynamic balancing
7. Finishing (polishing and lapping)
d. Quality test
15

16
LEICHT UND MÜLLER / STAMPING INDUSTRy
High pressure, high
speed and precision
imp:act 01/08
CERATIZIT is the technological leader worldwide in the field of the die industry
Every day we deal with stamped parts. No matter whether
it is furniture metal fittings or motor saws, small plug-in
contacts in computers, mobile phones or electric household
appliances – we can find stamped parts practically
everywhere. At the Reutte site CERATIZIT produces
carbide erosion blocks and formed parts for the die
industry according to customer drawings. One of the
CERATIZIT customers who has been trusting the
carbide expert for many years already is the Leicht + Müller
Stanztechnik company.
Stamping is the manufacture of flat or bent parts made
of sheet metal or foil strips using a stamping press and a
stamping tool. CERATIZIT produces carbide erosion blocks
and formed parts from which the customer makes die
inserts and punches through spark erosion (EDM and wire
erosion) or grinding. In fact the business segment ‘tool and
die industry’ has gained the world leadership in the past
few years.
The Leicht + Müller success story
The Leicht + Müller Stanztechnik company produces
stamped parts and tools for automotive electrics, telecom-
munication, household appliances and many other
industry sectors. The company was founded in November
1984 by Heinz Leicht, expert toolmaker, and Klaus Müller,
tool constructor, in Remchingen near Pforzheim
(Germany). Their priority was to enter the international
vanguard of tooling manufacturers.
Extract from the product range of Leicht + Müller:
approx. one billion of such parts are produced
here on the belt per year.
As far back as 1985 Leicht + Müller also started their produc-
tion of stamped parts. This second string to their bow not
only provided synergy effects but also decisive growth
impulses for the company. Today Leicht + Müller has 60
employees, who on a surface of 60,500 sq. feet produce
approx. 1.3 billion stamped parts (20-80 tons) per year on
10 Bruderer stamping machines.
Up-to-date stamping machines for razor blades
The company is particularly proud of the project for
Gillette (Procter & Gamble Group): together with other
companies Leicht + Müller developed a complex, fully
automatic stamping line for the further processing of razor
blades which are applied in the latest product ‘FUSION’.
The Americans requested a higher output from Leicht +
Müller as compared to the previous technology applied.
In the meantime three complete stamping lines have
been built at L+M which are suitable for batch production
and have been delivered to Gillette (two of them in
Boston/USA and one in Berlin/Germany). The most important
parameters of the currently most modern stamping
machines worldwide is the notably higher output, 500
strokes per minute, two blades with 13 laser points per
stroke respectively, a cleaning module, laser measuring
device and a camera in the stamping tool. Furthermore
robotics and conveyor belts to guarantee full automation
of the process are also utilized.

Interview with the leading management
quartet of Leicht + Müller
At Leicht + Müller the young generation is already
straining at the leash. The sons Timo Leicht and Marco
Müller have both completed a profound education.
Currently they are working in Sales, Marketing, project
management and in the company management, and
later on they will entirely take on the responsibilities of
their fathers, Heinz Leicht and Klaus Müller.
What is important in stamping technology and what
does that mean with reference to the carbide?
Marco Müller: “High precision, long tool life and profitability.
Carbide applied in high-performance stamping
technology has to be adapted continuously to the high
demands regarding tool life and will always be under
scrutiny when compared to ceramics.”
Is there a ceramic solution which can keep the pace?
Marco Müller: “This discussion has been going on for a
while. Of course we have already tested special ceramic
grades and the results in terms of wear and tool life
were sometimes even better than with carbide. However,
the application of ceramic is not worthwhile consi-
dering the high acquisition costs and the extraordi-
nary complexity of machining operations compared to
carbide. Up to now ceramic has not caught on in our
sector for economic reasons, and this is also not to be
expected in the near future.“
What are the trends in the stamping sector?
Timo Leicht: “Target prices on a globally minimum level,
but products of the customary best German quality. The
market is becoming more and more difficult and one
has to orient oneself based on low-wage countries. For
cost reasons one should actually buy components for
stamping tools there in order to remain competitive. The
quality however up to now does not meet the
standards of Leicht + Müller. So we have to concentrate
on cost reduction in our company, e.g. automation of the
processes. Another tendency is towards hybrid
components
Vision Control for one hundred per cent process security
Leicht + Müller offers an extensive service range. The
company’s designers work on 2-D (Cadda) and 3-D
(Solid Works) CAD work places from Daveg. The Pforzheim
based company is also able to offer prototyping and
pilot production. Last but not least it is involved in batch
production of stamped parts with Vision Control for
guaranteed product quality and ‘laser marking on the fly’
for 100 per cent traceability (every single part is provided
with a marking without slowing down the process).
LEICHT UND MÜLLER / STAMPING INDUSTRy
A family-owned company – two generations manage the high-tech
company Leicht + Müller. (From left: Marco Müller, Klaus Müller, Heinz
Leicht and Timo Leicht).
(plastic-metal composite material). An ever increasing
number of customers requests complete assemblies
from one source, that means stamped parts are
covered with plastic and provided with additional
components such as e.g. Reed sensors or resistances.
Since 2004 we have been able to offer this through
Leicht + Müller SySCOTEC.“
How did the partnership with CERATIZIT start?
Heinz Leicht: “That was at the beginning of the 80’s. At
that time Josef Lämmle was the segment manager. He
visited us frequently and asked if we were ready to test
his products, and he was successful.”
How do you assess the relationship with CERATIZIT?
Klaus Müller: “We are delighted with the carbide from
CERATIZIT! We appreciate speed, the large assortment
and above all consistent quality. In a business where
time pressure is enormous the business partners have to
be absolutely reliable. And we fully trust the CERATIZIT
team which has been serving us professionally for many
years. Carbide is really a matter of confidence!”
Combinations of metal and plastic
Leicht + Müller SySCOTEC (Systems, Components,
Technologies) was founded in 2004 and specializes in the
development and production of complete assemblies,
i.e. combinations of metal stamping products and plastic
parts. The new products from Leicht + Müller SySCOTEC
have brought customers such as Mercedes, BMW, TRW
and Continental Teves onto the scene. The first batch
production for level sensors in automotive windscreen
washing fluid started in 2005.
17

18
ÅKERS, SWEDEN
Roll machining with
CERATIZIT tooling
Customer report from the Åkers roll foundry in Sweden.
Machined with CERATIZIT tooling & inserts: the Åkers rolls weighing up to
sixty tons.
They weigh up to sixty tons and are the ‘flat makers’
in the roll mills: the huge rolls which convert the most
varied metals into sheet metal or strips. When machining
rolls the Åkers roll foundry in Styckebruk (Sweden) relies
on ceramic and carbide inserts from CERATIZIT.
Åkers Styckebruk is situated close to Stockholm in the
Swedish province Södermanland. The landscape is
extensive with little development. The motorway is
almost empty. Forests, meadows and lakes follow one
another. In this quiet, almost forgotten area operates the
largest roll manufacturer in the world: Åkers.
Since 1580 the company has been involved in casting.
Once Åkers produced cannons for the Swedish army. The
first roll was produced as far back as 1806. Today 1,400
employees produce high-quality rolls for sheet metal production
in 12 factories in 6 countries achieving a turnover
of 300 million euros (420 million US-dollars). Other Åkers
production sites can be found in Belgium, France, Slovenia,
the USA and recently also in China.
Every week up to 50 rolls are produced, more than
123,000 tons per year.
Every week the Styckebruk site produces between 35
and 40 medium-sized rolls and around five large rolls.
In 2006 the total production of the group amounted
to 123,600 metric tons, out of which 44% were sold in
Europe, 24% in Asia and 25% in North America. Åkers is
imp:act 01/08
Fireworks: an Åkers employee checks the temperature of the molten iron
before pouring it.
a solid family-owned company which successfully relies
on sound corporate values. The goal of Åkers is to
secure and further extend its position as the worldwide
leading roll manufacturer. Some of the Åkers customers
are steel works like Mittal, Tata and Bao Steel.
From the car body to the coin – everything made of sheet
metal
Sheet metal is the base material for numerous products
used in everyday life i.e. car bodies, housings of
electronic devices, coins and sinks are stamped or
formed out of sheet metal. These sheet metals are
produced in steel mills. Aluminum or steel billets are
rolled to sheet metal applying a warm forming
procedure with several roll passes at temperatures
between 1,300 and 2,200 °F until they have the required
thickness. Depending on the end product, cold rolling is
used to make hot rolled strips thinner and to improve the
surface quality.
Everything is larger
Åkers thinks big - and in this company everything is larger
than elsewhere; the workers in the halls resemble
miniature figures. Kennet Önnestig, Production
Engineering, describes the production process. “In a first
step the rolls are cast. For this purpose the requested iron
alloy is melted and subsequently poured into a casting
mould. The base material is iron scrap which is bought
in locally and then alloyed. Åkers applies two casting

procedures: conventional static casting and centrifugal
casting. During centrifugal casting the molten metal is
poured into a giant centrifuge which is built into a hole
in the ground. At 600 to 700 revolutions per minute the
centrifugal force makes sure that the molten metal is
hurled against the internal wall of the casting mould.” The
advantage of this method is that the surface of the roll is
not as rough as in rolls produced with conventional procedures.
Machining is therefore easier.
Up to 50% of the material is removed from every roll
In a second step the rolls are ground, turned, parted-off
and milled. This is where the rolls really ‘loose weight’:
up to 50% of the material is removed from every roll and
returned to the foundry as iron scrap. For the machining
of rolls CERATIZIT provides Åkers with ceramic and
carbide inserts. “In roll machining tool life and security
are crucial“, says Hans Axelsson, cutting tools sales
manager for North Europe. “The machining of a roll can
take several hours or even days, the process therefore
has to be stable, insert changes necessary due to
breakage or premature wear must be avoided, as this
would mean extra time. Sometimes the cutting depths are
enormous, even up to 4 inches.”
Interview with Kjell Andersson -
Purchasing Manager of the Åkers Group
Mr. Andersson, what are the most important quality
criteria of a roll?
Andersson: “A roll should be in action as long as possible
without having to be reworked as this always means a
lot of effort and loss of production time. The customers
usually rework the rolls themselves.”
How are the rolls transported to the customer?
Andersson: “The smaller rolls, let’s say up to 25 tons, are
transported by truck, the larger rolls by train or by ship.
Most customers have their own rail connection.”
What are the trends in the roll industry?
Andersson: “There are two trends: one trend is towards
high-tech rolls, these are rolls with a higher percentage
of alloys added. In this way the shell of these rolls
becomes harder and more resistant, so the service
life is longer, however they are also more difficult to
machine. The second trend is that grinding in the first
machining phase is becoming ever more important
than rough machining. Grinding however has the
disadvantage that the waste material can no longer be
ÅKERS, SWEDEN
Full concentration is required when copy turning. One inattentive
moment can totally ruin the 60 ton roll.
Åkers has been synonymous with top quality for almost 500 years. Hans
Axelsson, CERATIZIT Sales Manager for North Europe, Heikki Salovaara,
CERATIZIT Key Account Representative, and Kjell Andersson, ÅKERS
Supply Manager (left to right), in front of the historic cannons.
melted down directly as the grinding slurry is contaminated
by the coolant. I am therefore almost sure that grinding will
never entirely replace rough machining.”
How did cooperation with CERATIZIT begin?
Andersson: “In milling CERATIZIT (the former Plansee Tizit)
has been a reliable partner for many years. When we
extended our group by the plants in France we realized
that the turning, parting-off and grooving strategy at
these sites was very successful. The Thionville and Sedan
sites were supplied with tools from Cerametal. We took
a detailed look into this and decided that we would do
the same in Sweden.”
What are CERATIZIT‘s strengths?
Andersson: “CERATIZIT offers very good technical
support and implements projects quickly. Within a
year the new cutting strategy was introduced and the
process was stable. CERATIZIT does a good job and
makes also very good suggestions for roll machining. This
is exactly what we need!”
19

20
MaxiMill HEC
CERATIZIT’s MaxiMill HEC offers
performance advantages
CERATIZIT’s MaxiMill HEC cutters will help users maximize their productivity when machining Cast Iron components.
The launch of CERATIZIT’s MaxiMill HEC face milling
system at EMO 2007 is further proof of the high levels of
research and development taking place at its Reutte,
Austria manufacturing facility.
The MaxiMill HEC accepts CERATIZIT precision-
manufactured inserts of either carbide, ceramic or CBN
material, which provide up to eight useable edges.
These tangentially-mounted inserts are mounted in such
a way as to ensure maximum cutting performance and
cutter stability, while at the same time reducing the power
required to operate them at their optimum, making them
suitable to a much wider range of machine tools.
The result is a face milling cutter that will generate high
table feeds, long and consistent tool life, economic
application and process security. While MaxiMill HEC can
be used in virtually any C.I. face milling application it
will be of real interest to those companies supplying the
automotive sector where the volumes and component
types will suit its particular characteristics and
generate the maximum productivity and cost savings for the
end-user. Typical application areas for MaxiMill HEC would be
cast iron components such as contact faces of crank cases,
imp:act 01/08
cylinder heads, turbochargers and pump cases,
etc. “MaxiMill HEC is the result of an ongoing and
extensive development program at CERATIZIT”, says
Conan Jackson, CERATIZIT UK’s Sales Manager. “HEC is a
welcome extension to the existing MaxiMill range and
will provide many of our automotive customers with the
opportunity to maximize their machine capacity while
reducing tooling costs.”
With the LNHX 1106PNER inserts available in grades
CTC3215 (carbide), CTN3105 Si3N4 (ceramic) and
segmented CBN, the cutting data achieved is
impressive. For example, machining GG25 material at a
hardness of HB 180-220 is achieved at around 660 ft/
min, 0.009"/tooth feed rate with up to 0.19" depth of cut
and 3.11" width of cut. Similarly, GGG 70 material at a
hardness of HB 240-300 can be cut at 590 ft./min at a feed
of 0.0078"/tooth.

CERATIZIT develops new
high-feed face milling cutter
MaxiMill HFC is synonymous with rapid milling
CERATIZIT has developed a new tooling system for special
face milling operations. The MaxiMill HFC (High Feed
Cutting) system is synonymous with maximum feed and
chip removal rates.
High-feed cutting tools are applied where maximum chip
removal rates must be achieved in a minimum of time.
A typical application is rough milling of flat faces, for
instance in the field of mould and die construction.
MaxiMill HFC guarantees minimum vibration thanks to
a light cutting geometry with positive rake angles and
high chip removal rates. The inserts for this system have
a special chip groove specifically developed for this
application and are offered with the innovative Hyper-
Coat coatings. CTP1235 (for steel), CTP2235 (for stainless
steel) and CTC3215 (for cast iron). The combination of the
new HFC milling system and the latest CERATIZIT grades
MaxiMill HFC
guarantee maximum performance in terms of tool life,
surface quality and reduced tendency for vibration.
The optimized tool coating ‘hard & tough’, which is both
wear resistant (hard) and corrosion resistant (tough),
guarantees long tool life.
Flexibility concerning the coolant plays an important role
when high-feed milling. Every tool therefore possesses a
special coolant hole design which is particularly adapted
for minimum quantity lubrication.
The main application range of the new MaxiMill HFC
system is face milling with maximum feed (up to 0.12" per
tooth), plunging for the production of deep pockets and
with maximum chip removal rates (more than 91.5 cubic
inches/minute).
CERATIZIT has developed a new tooling system for special face milling operations. The MaxiMill HFC (High Feed Cutting) system is synonymous with
maximum feed and chip removal rates.
21

22
TITANIUM MACHINING
imp:act 01/08
Titanium machining of the future.
The new grade CTP5240 has been
adapted specifically for this task.
Weight reduction is the central requirement in the modern
aerospace industry for both civil and military aviation. The
industry sector responds to this requisite with new materials
such as carbon fiber. In this context titanium is also
gaining ever more importance in aircraft construction. In
fact structural components which hold the carbon fiber
components together are made of titanium, which is why
they can be considered the framework of modern aircraft
construction. Due to this tendency, structural components
made of aluminum are reducing in importance. Conse-
quently a considerably higher number of component
subcontractors will have to deal with this difficult to
machine material.
The CERATIZIT specialists have therefore made it their
goal to offer the industry a tooling solution which allows
high productivity and relatively low production costs for
components made from such challenging materials.
This is only possible by developing tools and inserts with
excellent performance in terms of tool life, cutting
parameters and process security. It is not sufficient to
upgrade existing carbide grades and geometries to
reach this goal. This is why our development team have
been concentrating on developing a completely new
combination of cutting material, coating and geometry,
adapted exactly to the special challenges of titanium
alloys right from the start:
• New carbide substrate with excellent heat resistance
properties.
• New coating with sufficient toughness, high wear
resistance and small coefficient of friction.
• New geometries for improved chip formation when
machining titanium.
The advantages of titanium alloys compared to other
materials are obvious. Titanium alloys are mainly
characterized by low density which is only a little more than
that of aluminum. Simultaneously they show twice as high a
strength so that structural components can be designed
slimmer and with lower weight. A disadvantage is their
bad machinability which has a negative impact
on manufacturing costs due to low cutting speeds
and short tool life. The most important reason for
this bad machinability is the extremely low thermal

Oliver Baum, Product Manager Aerospace.
conductivity of titanium alloys. Titanium conducts heat
about ten times worse than steel. Contrary to the
machining of steel the heat produced during the cutting
process is therefore not evacuated with the swarf, but the
major part of the heat is concentrated inside the tool or
the cutting edge.
This is where CERATIZIT gets things moving. A carbide
grade with substantially increased heat resistance was
developed. The main advantage of the new CERATIZIT
grade is really its heat resistance, which allows cutting
speeds up to -20% higher than comparable products from
competitors.
The recently developed grade which is to protect the
carbide substrate against abrasion also serves as a
heat barrier. This means the coating itself must have low
thermal conduction properties to prevent the heat from
reaching the carbide.
TITANIUM MACHINING
In order to minimize the heat generation, it is
essential that the coating has the smoothest possible
surface and the swarf can glide over the rake
face without substantial resistance. The recently
developed TiB2 coating by CVD from CERATIZIT totally
fulfills these specifications.
The inserts for titanium machining are customarily
provided with protective chamfers in order to stabilize them
at high temperatures, but this results in the disadvantage
of increased cutting pressure. Now CERATIZIT offers
the decisive competitive edge. Only the extremely heat
resistant substrate of the new CERATIZIT grade CTC5240
enables the application of inserts with very positive
geometries, without protective chamfer and with a light
edge hone to be used for the machining of titanium.
In this way cutting pressure is reduced which also limits
heat generation, and chip formation is greatly improved
through these extremely positive geometries. Additionally
compressed and lamellar chips are avoided, i.e. the
cutting pressure and subsequently wear is reduced.
All in all these effects result in a 20% increase in tool life
compared to other suppliers.
Figure 8: compressed chips ‘fan-fold’ due to insufficient chip formation vs.
spiral swarf.
23

24
RADO, CARBIDE WATCH CASES
Exclusive watches in classic
carbide from CERATIZIT
The Swiss watch manufacturer Rado relies on scratchproof cases
from CERATIZIT. Including interview with customer!
What do the punctual departure of a train, a
tenancy agreement, a game of chess and New Year’s
Eve have in common? They are all subject to time. A
contribution on the ‘time on the wrist’, the innovative watch
manufacturer Rado and CERATIZIT’s role in the
production of scratchproof watch cases.
The presentation of the first scratchproof watch in 1962
represented the start of Rado’s success story. Everything
began when Rado chief designer at the time, Marc
Lederrey, put forward a totally new idea. He was
constantly irritated when gold and steel watches,
which at the beginning looked beautiful, often showed
scratches after only a few days and subsequently had to be
polished frequently. Then, tungsten and titanium carbides
were only known as extremely resistant materials in the field
of high-tech production of special tools. “Making a watch
out of this material - that would be the solution,“ said
Lederrey. And Dr. Paul Lüthi, who was at that time the boss
of Rado, gave the go-ahead for this development. The
result: the first scratchproof watch in the world!
High-tech materials in watch production
Today Rado is one of the most important watch
manufacturers in Switzerland. The Rado group has been
part of the Swatch group since 1983 and already has
more than 300 service centers and more than 8,000
sales points. While other watch manufacturers apply
conventional materials such as gold, copper or steel,
Rado counts on high-tech materials of the future.
Lanthanum, ceramic, sapphire crystal, high-tech
diamond and last but not least carbide. The level of scratch
resistance of a material depends on its hardness. Hard
materials make scratches in softer materials: diamond makes
scratches in sapphire, sapphire in glass, and glass in metal.
Carbide case from CERATIZIT for the Swiss watch manufacturer
Rado: injection molded parts before sintering.
imp:act 01/08
The harder a material, the more brittle it is, and thus more
sensitive to impact. Resistance to scratches therefore is
not the same as indestructibility.
Rado has never only focused on beautiful watches.
The main decision has always been the selection of the
material. In this way design and material combinations
are developed which perfectly combine the two
functions of a watch: a modern piece of jewelry and a
functional time indicator.
Carbide from CERATIZIT for the top watch brand Rado
CERATIZIT has supplied Rado with carbide cases for
decades. The development and the production of
the cases started at the beginning of the 1960‘s at the
Reutte site. Now they are produced in Mamer,
Luxembourg and are then subjected to several
machining processes at Rado’s subcontractors
until they become high-quality watches. Marc Lanners,
production manager of the watch case line in Mamer:
“The most tricky thing when producing watch cases is
aesthetic quality. The preparation of the feedstock
(a mixture of powder and binder) is of maximum
importance in order to be able to fulfill the quality
requirements. Both surface and form have to be
absolutely perfect. This is why quality control is obviously
extremely important for these products. We have very
precise control systems.”
“We produce tens of thousands of carbide watch
cases per year, today we have five models,” says Hans
Müller, business segment manager of special indu-
strial wear parts. “Even for these high-quality products the
life cycle is continuously decreasing. We must therefore
react ever faster. The latest case model was developed
within only four months by CERATIZIT.”
The external part during final polishing.

RADO, CARBIDE WATCH CASES
Interview with Peter Oppliger, Rado Purchasing Manager
How did the partnership with CERATIZIT start?
Oppliger: “The partnership began in the middle of the
1980’s. After carrying out a detailed study about batch
production of our model ’The Original’ whose success
has been unparalleled since 1962, we decided to
modify our production method. We no longer wanted
to produce the watch crown of our top model through
pressing but through injection molding. So we referred
to Cerametal in Luxembourg.“
Why does Rado count on carbide from CERATIZIT?
Oppliger: “CERATIZIT has a reputation as a reliable
business partner. Its extensive know-how in the field of
carbide injection molding enables embossing of our
logo in the watch case. In this way it’s also easier for us
to proceed against counterfeits.“
What is important with regard to the watch cases? What
are the special characteristics and properties?
Oppliger: “Since its foundation 50 years ago Rado has
always been a watch manufacturer who has focused
specifically on technology and innovative batch produc-
tion processes. At the time of the market launch the
objective was to create a watch on which time would
leave no traces, i.e. a scratchproof watch. For this
purpose you need a hard and sufficiently shockproof
material. Carbide combines these characteristics
and in addition is a visually pleasing material, which is
extremely important for watches.“
What are the current projects and further developments?
Oppliger: “Following its pioneering spirit Rado is working
on several projects simultaneously; however, we are
unable to discuss anything particular about them right
now. CERATIZIT has offered us a very interesting new
carbide which is light and hardly releases any nickel. So
it can continuously be in contact with the skin. This new
material allows us to think about many possible applications
for the future.“
Are there any materials which compete with carbide?
Oppliger: “In a certain respect high-tech ceramic
manufacture which was introduced in the watch
industry by Rado, is a carbide competitor. Its lightness
and hypoallergenic properties make this ceramic a
material which can be easily worn on the wrist without
complications.“
What would CERATIZIT have to optimize in order to score
additional points and to get more business?
Oppliger: “As for every other supplier for us it seems
important to maintain close cooperation and good
communication. As these are luxury articles where
aesthetics and quality are basic requirements it is
obviously decisive to guarantee consistent and
impeccable quality.“
25

26
HILTI, DRILL MANUFACTURER
CERATIZIT produces
carbide bits for HILTI drills
Customer story on the development of tailored carbide bits
The demands on the carbide follow from the practical requirements at
the construction sites, which according to up-to-date market analyses
are steadily increasing.
HILTI, the CERATIZIT key-account customer in the
field of stone working is based in the Principality of
Liechtenstein. HILTI has been buying all carbide bits from the
carbide expert CERATIZIT since 1985. As: on the
interface between the drill and the base material the
carbide from CERATIZIT shows its strength, thus ensuring
long tool life. Jan Doongaji, Senior Vice President Business
Unit Drilling & Demolition at HILTI states: “It is exactly the
products made of carbide from CERATIZIT that customers
perceive as distinctive.”
“In the 1990’s HILTI, the worldwide market and technology
leader in the professional drill business, together with
CERATIZIT developed the idea of launching a welded
solid head drill. That was the hour of birth of an intensive
development cooperation”, remembers Dr. Wolfgang
Böhlke, Head of the Wear Part Development at
CERATIZIT Luxembourg. The solid head solution of the HILTI
drill is still unique today. There are no single carbide pins
2
1
imp:act 01/08
On the interface between the drill and the base material the carbide
from CERATIZIT shows its strength, thus ensuring long tool life.
and tips which are inserted into the steel body, but only
one head which is brazed or welded onto the steel body.
Georg Schmid, Business Unit Manager of the tool
production at HILTI explains: “As the drill head consists
entirely of one carbide only, there is more freedom in
terms of cutting edge geometry which subsequently
results in better drilling performance.”
Unique solid head solution wins EPMA Award
The joining process is regarded as the most delicate step in
drill production. Schmid: “Carbide and steel are rather
unequal partners when it comes to properties like brittle-
ness and thermal expansion. The critical area with
regard to fractures is undoubtedly where the steel
and the carbide are connected.” In order to avoid this
problem HILTI and CERATIZIT developed a solid carbide
drill with gradient structure. This means that the carbide is
extremely hard on the tip but rather tough on the steel side.
The gradient in the carbide combines two characteristics:
good wear resistance on the tip and a stable welded
Solid head drill with gradient zones in C3X geometry, 0.16 - 0.63" – the
best powder-metallurgical development at the EPMA conference.
Carbide with gradient structure: 1 Good wear resistance on the tip,
2 Stable welded connection with the steel shank.

connection with the steel shank. The solid head drill
with gradient zones which was developed by HILTI and
CERATIZIT together with the geometry C3X was even awarded
a prize at the EPMA conference 2006 in Gent (EPMA =
European Powder Metallurgy Association).
“The cooperation between HILTI and CERATIZIT also
includes basic elements such as the development of
new cutting materials“, says Dr. Till Cramer, Head of the
Consumables Development BU Drilling and Demolition
at HILTI: “HILTI strives for consistent differentiation in the
market. The cutting material represents the key technology
for the differentiation of a drill,“ says the drill expert. “We
really appreciate CERATIZIT’s extraordinary willingness to
implement such developments with us.” Vice President
Doongaji adds: “It has also to do with trust and tradition.
We have already developed several generations of drills
together, which enables us to move on to the next level of
competency together.”
Demands on the carbide in the drilling industry
The demands on the carbide result from the drill itself,
and these demands are steadily increasing. The material
to be machined is becoming ever harder, and the
carbide bits are characterized by ever higher performance
capacity. CERATIZIT head of development
Böhlke says: “The demands on the carbide are basically
maximum wear resistance when drilling very abrasive
concrete and sufficient toughness when encountering
reinforcements in the concrete. This also requires a stable
welded connection with the steel shank of the drill.“ And these
capabilities are tested at HILTI in an exceedingly demanding
laboratory for new developments that focuses on high
quality. Dr. Cramer says: “In addition to drills HILTI also
HILTI, DRILL MANUFACTURER
develops heavy duty hammers and combi-hammers.
In this way the two components, tool and carbide
bit, can be perfectly adapted to each other.
Those who drill several hundred holes a day
realize the difference.”
Drill production in Kaufering
The drills are actually not produced in Liechtenstein but in
Kaufering in Bavaria. HILTI’s drills range from diameter 0.2"
(length 4.72" ) up to diameter 1.57" (length 36.22").
HILTI relies on innovative solutions for construction sites
HILTI as a brand name long ago became
synonymous with heavy duty drills and other tooling systems
amongst professionals; the company employs 20,000
people and stands for innovative solutions for professionals
at construction sites. And the results are stunning. In
2007 the HILTI group showed a double-digit growth for
the fourth time in a row, launching more than 30 new
products on the market every year.
HILTI drills with CERATIZIT carbide bits are supplied throughout the world.
27

28
HPC 12, FRANCE
Unique milling
concept with
substantial
potential for savings
CERATIZIT develops the new MaxiMill
HPC 12 milling cutter with an
international team
With its segment strategy in the business unit end-users
of the cutting tool division, the carbide expert CERATIZIT
is particularly successful as the company counts on
segment-specific and customer-specific products as
well as on tailor-made solutions. In this way the global
player in the field of advanced carbide solutions also
proves its competence in niche markets. International
cooperation within the group plays an important role
here. An international team developed a unique
milling concept for the automotive industry, namely the
aluminum cutter MaxiMill HPC 12.
A complete tooling concept in only six months
The starting point of the project was a meeting at an automotive
customer’s in July 2003. CERATIZIT made an offer to
the production manager to deliver new tools which would
meet the increased requirements within only six months.
An extremely ambitious deadline chosen by CERATIZIT
itself. The CERATIZIT project team had an additional goal:
a new flexible tooling concept should be developed
which would be suitable for the majority of applications in
aluminum milling for the automotive industry.
This development project brought the MaxiMill HPC12
concept into being. The idea was to develop a milling
concept where the number of teeth, the form of the
cutter body, the coolant, the cutting edge geometry, the
rake angles and the cutting materials (CBN, PCD) could
be modified.
MaxiMill HPC 12 – the properties
• Low cutting forces thanks to positive rake angles
• Reduced deformation of the components
• Reduced built-up edge
• Increased tool life
• Tool body made of steel
• Precise repeatability during insert change
• Very high stability and longer tool life
imp:act 01/08
• Options: bimetallic version (steel ring and aluminum core).
• High speed – high performance
• Reduced work piece heating
• Maximum productivity
• Optimised design of tool and insert seat
• Axial fine adjustment
• Short setting time through easy handling
• Fine adjustment = 0.004"
HPC 12 allows savings up to 30 %!
The automotive industry in particular places high
demands on their tools. The processes in this field must
not only be quick and stable, they also need to be
highly consistent and predictable. Furthermore, in most
of the cases productivity has also to be improved. In
a test with an AHPC 100R12.12 milling cutter MaxiMill
HPC 12 showed its abilities and its saving potential at a
CERATIZIT customer‘s who produces gear box cases made
of aluminum AS7. Applying the HPC 12 milling cutter the
CERATIZIT customer was able to reduce the machining
time by 11.3 seconds (at the beginning the machining
time amounted to 30.5 seconds and was reduced to 19.2
seconds thanks to MaxiMill HPC 12). A surface quality of Rmax
< 6µ – was requested, and CERATIZIT even obtained
4.42µ. The test is also very significant for its extreme
cutting data:

The aluminum milling cutter MaxiMill HPC 12 convinces through its quick and simple adjustment and the high surface quality.
MaxiMill HPC12: tool body made of steel, precise repeatability during the
insert change, very high stability and long tool life.
• vc = 15,459 ft./min
• n = 15,000 rev./min
• f = 992.12 "/min
• fz = 0.0055"
These excellent results can be attained with the HPC
12 milling cutter thanks to its stability and its simple and
precise fine adjustment.
International cooperation – voices of the CERATIZIT group:
The idea and the drawing for the HPC 12 concept come
from France. The project was finally concentrated at the
automotive segment at CERATIZIT Reutte, Austria.
HPC 12, FRANCE
Jürgen Duwe from the development department in
the BU end-users: “It was one of the first projects where
employees of several sites were involved. Despite
different languages and cultures the project was a
resounding success. We got to know each other better
and are now in closer contact. This will definitely be an
advantage for future projects.”
“I consider the tooling system HPC 12 a real ‘door opener’
for companies of the automotive industry,” says Tinus
Zuetenhorst, sales manager of CERATIZIT Nederland.
“Ever since we presented this tool we have had a much
stronger presence and actively invited to carry out tests.
We have already been successful at three companies
with the tool – this looks very promising!”
Gonzalo Artaega, sales representative at CERATIZIT
Ibérica about the HPC milling system: “This solution has
enabled us to offer our customer Fasa Renault Valladolid
an efficient and economic tool which is better than the
competitors’ tools. Above all, the low weight, the long tool
life and the good surface quality produced by this milling
cutter have convinced our customers.”
29

30
BGH EDELSTAHL, Germany
A win on points:
bar peeling vs. turning
Bar peeling with CERATIZIT tools at BGH Edelstahl
From the raw forged blank to the polished bar – the
carbide expert CERATIZIT proves its expertise in the field
of bar peeling with practical examples. The mechanical
engineering segment in the CERATIZIT cutting tool
division / BU end-users focuses on the development of
tools for bar peeling, an important area in the field of
cutting tools.
Bar peeling is a machining method where producing
heavy swarf. It is the machining of forged bars to remove
oxide, chilled skin and surface cracks. During the peeling
operation the bars are given the requested surface
quality, dimensional accuracy and roundness. Bar
peeling is suitable for the machining of various
material types: for example tempered steel, bearing
steel, tool steel, high-speed steel and spring steel, high
alloyed also stainless steels, and even for titanium.
The results are semi-finished products which are mainly
delivered to the oil industry and the general
mechanical engineering sector. Automatic lathes
produce the most varied turned parts. Later the bars may
be machined as mandrels, axles for wind turbines, gears,
piston rods and shafts.
Bar peeling: from the blank steel to the machined bar
During the peeling operation the bar is moved through a
rotating peeling head, with a radial direction of cut. The
peeling head in this case has four cartridges, each with
one to three inserts which are all in contact with the bar.
The inserts serve for roughing and finishing.
Bar peeling in detail
1. Heating the blank steel in a furnace
2. Forging or rolling of the hot bars
3. Annealing and pre-alignment of the bars
4. Taking samples for quality assurance
5. Elimination of oxide, chilled skin, and surface
cracks in the peeling facility taking into
account the required dimensional accuracy
and surface treatment
6. Straightening of the bar in the press to balance
stress and strains which are caused by bar peeling.
7. Final ultrasonic checking of the peeled bar for
cracks and other imperfections
8. Available upon request: grinding of the bar in a
belt grinding machine
imp:act 01/08
Impressive: at BGH in Siegen bars up to 60 feet long, are turned by a
Kieserling & Albrecht machine with a length of 164 feet.
CERATIZIT carbide tools for bar peeling – the robust ones for the hard
work.
A practical example: bar peeling at BGH Edelstahl in
Siegen, Germany
Boschgotthardshütte (BGH) Edelstahl in Siegen has been
a CERATIZIT customer since 2005. BGH produces stainless
steel and special alloys suitable for the toughest applications.
At BGH in Siegen bars up to 60 feet long, are turned
by a Kieserling & Albrecht machine with a length of
164 feet. With this facility BGH machines around 4,100 tons
of bars per month, producing 350 tons of swarf.
CERATIZIT makes the roughing insert RNMH 5018MOS00-R50
CTC1635, which is applied up to a cutting depth of 0.28",
and the finishing insert, yNUF 201220S50-M50 CTC1125,
which thanks to its positioning in the cartridge achieves a
constant cutting depth of 0.06".

Elimination of forging skin, chilled skin, and surface cracks in the peeling facility.
Interview with Jost Kretzer,
plant manager at BGH Edelstahl
When is peeling applied instead of turning?
Kretzer: “Peeling is mostly applied for long cylindrical
work pieces, i.e. bars. Shafts with a step or bars with a
diameter larger than 11.8" are turned.“
What are the advantages of bar peeling?
Kretzer: “One of the main advantages is the simul-
taneous application of four tools; this means feed rates
four times higher than with turning. There is also reduced
vibration in peeling because the bar is held closer to the
cutting tools. The entire peeling process is considerably
more stable and thus more resistant to vibration, through
which performance is also increased.
Furthermore the material allowance for bar peeling is
smaller compared to classic centre turning. The bar
BGH EDELSTAHL, Germany
is held centrally, extra support such as fixed stays or
change of clamping as in turning are not necessary.“
What are the risks in bar peeling?
Kretzer: “Clearly, the breakage of the insert. If an insert
breaks at a feed rate of 0.59 to 0.7" per revolution, the
entire cartridge is ruined, or even all four cartridges. The
higher forces which can occur after the insert breakage
cause the peeling head to start turning the bar instead
of peeling it. This leads to very high costs as the 22 guide
rolls of the peeling machine and the bar are damaged.
But before the insert breaks, the pressure rises and the
facility requires more power, which can be heard very
well. In this case sensitivity is necessary: it is important
to change the insert at the right moment to avoid this
risk.“

32
HUNTING OILFIELD SERVICES, NETHERLANDS
A small device with a big effect
CERATIZIT customer story: improved security in threading
operations for the oil industry
The CERATIZIT customer Hunting Oilfield Services
BV (Netherlands) provides high-quality tubes and
couplings with threads. The tubes are applied worldwide
for the production of oil and natural gas. Until a short time
ago the swarf resulting from the production of couplings
stayed in the work piece and was removed manually.
Dangerous work, as hot and sharp chips were thrown
around and could injure the workers. CERATIZIT found a
quick solution.
A show of strength: the exacting process of winning oil
Tubes and couplings are exposed to enormous stress
during oil extraction as most oil deposits are four 3 miles
beneath the surface of the earth. A boring head or trepan
has the difficult task to ensure access to the oil.
The boring tool consists of steel tubes placed at its ends
which are connected by threaded joints to form the
pipe string and drill string. Shortly before the trepan
reaches the oil deposit the drill string has a length
of several miles and, weighs around 110 tons which
corresponds to the weight of a large diesel locomotive.
This enormous weight is suspended on the upper thread,
the quality of which therefore has to fulfill exacting
demands.
Precision and security: threading
Hunting Oilfield Services BV in Velsen-Noord, northwest
of Amsterdam, specializes in problem solutions for
oil and gas extraction. Some customers of the affiliate
The new solution from CERATIZIT: the swarf is drawn from inside to
outside and falls out of the work piece.
imp:act 01/08
Hunting PLC group are Gaz de France, Total Fina and
Exxon Mobil. Hunting Oilfield Services was founded in 1986
and today has around 60 employees who work seven
machines around the clock (shift work).
Hunting Oilfield Services produces the threads in
tubes and couplings which are applied for oil and gas
extraction. The tubes mainly come from Japan and
have a length between 32 and 42 feet. 75 % of the tubes
consist of high alloyed chromium steel, the remaining
25 % of low alloyed steel with medium strength (P110, C95
or L80). Threading both sides of the tube takes about 15
minutes. One cutting edge of an insert lasts for about 10
to 14 threads.
Risk of injury at the workplace
To avoid damage of the work piece and ensure longer
service life of the insert it is absolutely necessary to
evacuate the swarf as fast as possible. Until a year ago
at Hunting the swarf resulting from threading operations
remained in the coupling. From there the workers
extracted it by hand, the CNC machine remaining in operation
and the door open - a dangerous situation. When
turning, the spindle in the CNC machine rotates very quikkly,
hot sharp swarf is flung about and coolant sputters
around. The danger of injury is very high.
The Holland Institute for work security (ARBO) criticized
the machine and demanded that Hunting operate the
machines securely.
Quality control: the work piece is manually checked for ruptures.

The danger was recognized and averted
The CERATIZIT engineers Jackie Roland and Fabrice
Casagrande (the latter being the business segment
manager cutting tools/oil industry at CERATIZIT
Luxembourg) were asked for advice. Their solution
was to produce the thread from the inside towards the
outside of the component so that the chips are
eliminated automatically. For this purpose they
designed a special tool holder which positions the insert
HUNTING OILFIELD SERVICES, NETHERLANDS
securely. Even if it is drawn into the opposite direction as
is here the case.
The new tool holder concept ensures that the chips are
transported on the shortest way from the work piece
and that the coolant stream is precisely directed onto
the cutting edge. The Dutch Institute for work secu-
rity was satisfied with this solution so that production was
allowed to go on at Hunting without any interruption.
Interview with André Verbiest, Manufacturing Manager
of Hunting Oilfield Services BV
Mr. Verbiest, what is important when threading for the
oil industry?
Verbiest: “We are under great time pressure. We must
therefore produce quickly and without interruption. If
we do not supply, the work on the oil platform comes
to a halt. This costs a fortune. A further point is that the
connections between the couplings and the tubes,
namely the threads, are standardized. It is absolutely
necessary that the thread be gasproof and have a
consistently high quality.”
What characterizes the cooperation with CERATIZIT?
Verbiest: “I have noticed a combination of determination
and technical competence. The representatives
believe in their product and are really behind it - this is
easily perceivable. Furthermore, CERATIZIT does not try
to sell us stock articles after a delivery time of 12 weeks,
but offers exactly the solution that we need after only a
couple of weeks. This is what we like in particular.”
What is the quality of the CERATIZIT products?
Verbiest: “The double clamping system is very
good. you can see what is going on and the insert is
positioned perfectly safely. Recently we have
conducted numerous tests where we achieved
considerably better results than our competitors, as we
applied CERATIZIT inserts.”
What could CERATIZIT improve?
Verbiest: “CERATIZIT takes little things into account,
which make a big difference in customer service. For
example, the packages they deliver have little grips.
So, both the freight carrier staff and our staff carry the
packages instead of throwing them. This causes less
transport damage which subsequently has a positive
effect on the cooperation. So I can only say: keep
going!”
75 % of the tubes from Hunting Oilfield Services BV consists of high alloyed chromium steel, the remaining 25 % of low alloyed steel with medium strength
(P110, C95 or L80).
33

34
COATED CBN
imp:act 01/08
CERATIZIT successfully applies CBN
with a world innovation coating
On the occasion of AMB (9 th -13 th September, Stuttgart, Germany)
CERATIZIT will for the fi rst time present a coated CBN
(cubic boron nitride) material.
In 1969 GE (General Electric) launched cubic boron nitride
for the fi rst time under the name ‚Borazon’ as a revolutionary
development in the fi eld of extremely hard grinding
material. CBN does not occur naturally, but is produced
synthetically (high-pressure synthesis) and, with a hardness
twice as high as silicon carbide (SiC) after diamond ranks
as the second hardest material.
CERATIZIT supplies the most important producer of CBN
materials with the tools necessary for high-pressure
synthesis (anvils and dies).
CBN has been known as a cutting material for over 30
years and shows its strengths particularly when turning
hard materials (hardness > 58 HRC), such as hardened
steel or chilled castings: CBN is characterized by extreme
hardness and excellent heat resistance as well as suffi cient
toughness for this application area.
CERATIZIT has been selling CBN inserts for many years. The
product range also includes milling tools to an increasing
degree. The stress the tools are subjected to during
these milling operations is caused by interrupted cut,
thermal changes and oxidation, and represents one of
the threshold applications of CBN.
The new HyperCoat grade CTL3215 – CBN has a new lease
of life
Thanks to the application of a suitable and functional
coating, the milling range has been extended as both
process security and tool life have signifi cantly been
increased. Furthermore it has become evident that
these improvements also have a positive impact on
turning operations of grey cast iron and steel castings
under diffi cult conditions.
HyperCoat coating is the secret
CERATIZIT has developed and patented a specifi c
PVD coating for CBN cutting materials. This innovative
coating is the answer to the complex demands on a material
applied in milling operations which are characterized
by stress variation, thermal shock and oxidation. The
recently developed coating is based on an innovative
composition which shows signifi cantly better resistance to
oxidation and simultaneously excellent wear resistance,
especially when it comes to high application temperatures.
Compressive stress resulting from the PVD coating procedure
provides the new HyperCoat coating with higher
toughness and last but not least with more reliability for the
tooling system.
CTL3215 ensures success
Thanks to CERATIZIT’s coating approach the application
range of CBN tools has been substantially extended. At
last it is now possible to mill also hardened steel and cast
iron in a notably better way. The coated CBN solution
from CERATIZIT will mainly be applied for fi ne or medium
milling operations with cutting speeds up to 1,000 meters
per minute, depending on the application. The tooling
solution therefore requires stable machining conditions
and is applied without cooling lubricant. In general tool
life is increased by 30 to 40 % compared to uncoated
CBN.

New: OvalFlex
The oval all-rounder for aluminum wheels
Aluminum wheels are more popular than ever. Today
almost every new automobile is provided with aluminum
wheels, with a tendency to rise. The variety of types and
design is continuously increasing. Requirements with
regard to productivity, process security and flexibility
for aluminum wheel producers are therefore also
increasing.
This is why CERATIZIT has developed OvalFlex tailored to
the specific needs of the operators. The tooling system
is the all-rounder that the aluminum wheel market has
eagerly been waiting for a long time. With its oval form
and silvery glitter colour it is applied to produce real
‘gems’ – while at the same time it convinces through a
series of innovations.
Higher stability and improved performance
“With OvalFlex we have succeeded in developing a highperformance,
modular tooling system with maximum
stability and reliability“, says Dr. Uwe Schleinkofer,
Head of the Development Department Cutting Tools at
CERATIZIT. “The oval form of OvalFlex makes the tool’s
assembly height larger than in normal round tools.
Therefore improved stability and performance are
guaranteed for the entire tooling system.”
The new oval interface connects the tool shank with the
tool head. Four tapered surfaces around the interface
provide accurate connection with the location face in
both radial and axial direction.
The advantages at a glance:
• High flexibility
(special tools no longer necessary)
• Tool life increased up to 100 per cent
• Reduced logistics
(standardized interfaces and insert seats)
• Maximum stability
• Maximum application security
Makes aluminum rims really beautiful: OvalFlex
OvalFlex
“Thanks to its oval form OvalFlex offers improved stability
and performance for the entire tooling system.”
Dr. Uwe Schleinkofer, Head of R&D Cutting Tools.
High flexibility
Furthermore on the OvalFlex system various tool heads
can be mounted on the shanks. “This ensures high
flexibility. “Special tools can be avoided to a large
degree,” according to Dr. Schleinkofer.
For OvalFlex CERATIZIT has developed new inserts (X32):
larger than common inserts, extremely stable and
protected against drawing cuts by their tapered form.
“All these inserts with different radii can be used in the
same tool“, emphasizes the Head of the Development
Department.
Conclusion: only OvalFlex makes aluminum rims really
beautiful!

36
AUSTRIA ALU-GUSS
The individual hallmark of the car
In the field of rim production Austria Alu-Guss relies on OvalFlex
from CERATIZIT.
Its design is the eye-catching feature of a car, providing
it with a personal touch: the aluminum rim. It is en vogue
as never before, and almost every automobile today
has aluminum rims as a standard feature. The variety of
types and design is continuously increasing. OvalFlex,
a modular turning tool developed by CERATIZIT, fulfils
the demands of the manufacturers regarding flexibility,
productivity and process security. The CERATIZIT
customer Austria Alu-Guss, who is one of the big players
in the sector (production volume of three million
aluminum wheels per year) has successfully applied
OvalFlex since the beginning of 2007.
The tendency: exclusive styling
Light metal wheels are applied in formula 1 cars, trucks
for heavy load transports and also in the aerospace
industry. The major share however are aluminum wheels
for automobiles where basically two types may be
distinguished: one-piece rims in one casting and multi-
piece rims which are connected by screws and consist of
a rim bed, a rim crown and a centre hub.
Austria Alu-Guss is based in the Austrian Ranshofen,
has been a member of the Borbet group since 1996
and develops and produces aluminum rims for Audi,
BMW, Mercedes, Opel, GM, Porsche, VW, Seat etc. The
company has 730 employees and offers wheel types with
annual quantities over 100,000 pieces as well as small
batches of less than 1,000 pieces. The trend is towards
smaller batch sizes whereas the styling is becoming
increasingly varied. “The most important task is to
technically implement the customer’s wishes regarding
the design,” says Alois Grömer from the mechanical
machining department at Austria Alu-Guss. “A light
metal wheel almost always represents a compromise.”
Stability and high performance: OvalFlex
On a conveyor belt the blank aluminum rim is transported
to the CNC machine, where it is turned at around
2,000 rev/min applying OvalFlex.
OvalFlex has exclusively been developed for machining
light metal wheels. The oval shape differs from the
conventional round shape of copy turning tools. In this
way the tool does not need so much space and can go
deeper into the rim. The height however has remained
the same and guarantees stability which increases
profitability, as high stability makes larger depths of cut
possible.
imp:act 01/08
The main attraction: the new oval interface connects
the tool shank with the tool head. Four tapered surfaces
around the interface provide accurate connection
with the location face in both radial and axial direction.
Thanks to this highly precise connection it is almost
unnecessary to make corrections.
High flexibility, reduced logistics
Another advantage of OvalFlex is its modularity.
Different styles of tool heads can be mounted on the
adapters. In addition, different angles can be set on
the tools. A system which ensures that aluminum wheel
manufacturers benefit commercially and logistically, as
thanks to modularity they need fewer special tools and
the necessity for stock keeping is decreased.
High-quality metal is melted and the respective alloy formed so that the
wheels can be cast in low-pressure machines.
The overhead conveyor transports the aluminum rims to the lacquering
facility.

Exact positioning of the inserts
For Ovalflex CERATIZIT has developed new inserts. The X32
insert is larger than the common inserts and extremely
stable. Thanks to its top faces it may be positioned
precisely, assuring that the insert also absorbs the cutting
forces better. The X32 insert is even protected against
drawing cuts in the best possible way through the shape
of the top surfaces.
The steps in the manufacturing process of light
metal wheels:
1. High-quality metal is melted and the respective
alloy formed so that the wheels can be cast in
low-pressure machines.
2. An x-ray facility checks every wheel for faults in
the casting.
Interview with Alois Grömer
from the mechanical
machining department at
Austria Alu-Guss
Which step is the most tricky when manufacturing
aluminum rims?
Grömer: “This depends on the design. In general you
could say that a combination of all processes leads to
a good product. When producing a wheel made of
easy-to-machine material there may be problems during
casting. But then, with a wheel that can easily be cast,
there may be problems during machining. Various
special lacquers may also cause problems during
production.”
What is important with regard to the hard metal?
Grömer: “We have to find the ideal composition of the
carbides. The higher the silicon content in the aluminum
alloy, the faster wear occurs.”
What was the most complex rim you have ever
produced?
Grömer: “It was a Rolls Royce rim, a so called ‘Nature
Wheel’ which was very difficult to machine because of
its thin walls.”
What is the tendency in the aluminum wheel sector?
Grömer: “The tendency is towards individuality and
light construction. The unsprung masses have to be
reduced, this means a consistently light construction of
the wheels.“
AUSTRIA ALU-GUSS
3. A heat treatment taking several hours increases
the strengths of the wheels.
4. The wheel profile is turned on CNC machines,
subsequently the valve hole and the holes for
the bolts are drilled. Everything is done with
tools from CERATIZIT.
5. All wheels are checked for unbalance, cleaned
and then finished with lacquer. A 3-layer structure
of the lacquer protects the wheels while
being used.
6. Finally a fully automatic helium pressure test
facility verifies if the wheels are leak-proof.
The Austria Alu-Guss rim experts: Alois Grömer (mechanical machining)
and Manfred Niedermüller (continuous improvement process and
engineering), from left.
How long does a cutting insert last on average?
Grömer: “It is very difficult to make a precise statement
as the service life of an insert depends on numerous
factors. By rule of thumb however you can say that a
cutting edge can work up to 400 rims (standard rim
17 inches).”
What is CERATIZIT‘s strength?
Grömer: “CERATIZIT has always been one of the leading
companies in the field of aluminum machining. With the
recently developed modular OvalFlex tooling system
CERATIZIT has succeeded in offering a completely new
and stable system which shows great performance
capacity and flexibility. This is where I can see an
essential advantage compared to competitors.”
37

38
ZRINSKI, CROATIA
Aluminum component
A ZRINSKI employee checking the quality of an
aluminum component
Find the right tooling partner:
ZRINSKI Tehnologija machines
with CERATIZIT
Application report at ZRINSKI Tehnologija in Croatia
CERATIZIT customer ZRINSKI Tehnologija in Northern
Croatia has already filled half of its new hall with CNC
machines. Marijan Cepanec, production manager for
turning, explains: “We still have a lot of plans. At the
moment we have 18 machine plants, and another four are
planned for this year.”
ZRINSKI Tehnologija is an affiliate of the German ZRINSKI
AG and over the years has become an expert in the field
of design and production of high-quality special products:
medical systems, aerospace components, mechanical
engineering, precision engineering and antenna instal-
lation. Using aluminum, titanium and other materials ZRINSKI
Tehnologija produces spine implants, bone plates,
kinematic modules for aircraft seats, watch cases and
surfaces of parabolic reflector antennas. Production manager
Cepanec states: “Per year we produce up to 2000
seats for Lufthansa’s Business Class, a typical example of
our service: highly precise parts delivered just in time.“
Further premium customers and projects are Siemens
(assemblies and A-parts) and IWC (watch cases) as well
as the core piece for the ‘ear of the world’, the surfaces of
the radio telescopes in the Atacama desert in Chile.
imp:act 01/08
Find the right tooling partner: CERATIZIT
When manufacturing such high-quality products, the
choice of the tooling partner is a crucial decision. Production
manager Cepanec: “80 per cent of the carbide tools
applied at ZRINSKI Tehnologija are from CERATIZIT. The
demand for tools is very high ranging from drills to
high-speed tools.”
Željko Domislović, production manager for milling states:
“The great thing about working together with CERATIZIT
is their short response time. The tools are always on time,
which is one less worry. Tools for test purposes are also
always delivered in a short time. Cooperation is extremely
uncomplicated. Problems are discussed openly and
together we think about how things can be improved
upon. In addition there are regular visits, which has
ensured that we are on good terms with each other.”
“We are delighted with the cutting tools from CERATIZIT!”
The cutting tool engineers at ZRINSKI Tehnologija know
that CERATIZIT does not only offer highly efficient
tools for aluminum machining. Domislović: “We are
really delighted with the cutting tools for titanium

Cutting tools for medical systems: ZRINSKI produces titanium implants with
tools from CERATIZIT.
machining. When machining a titanium work piece
(3.7164, Ø21 x 6.46") with a CERATIZIT solution we
machine 130 parts per cutting edge, which means twice
as much as with the competition’s product and a higher
spindle revolution number (1400 rev/min as opposed to
1000).“ “The machines at ZRINSKI Tehnologija operate at
full speed, and it is not easy to find the time for tests“, adds
Aleksander Nišević, CERATIZIT sales manager for Croatia.
“With such results however the tests pay off very quickly.”
Small parts for the kinematic modules of aircraft seats.
ZRINSKI, CROATIA
ZRINSKI produces and mounts a module of the kinematic
modules for the Business Class seats of a leading aircraft
manufacturer. This module consists of several titanium parts.
From tool mechanic to entrepreneur
Josef Zrinski, born in Croatia, moved to Germany at the
age of 14. In 1984 (Zrinski had in the meantime become
a tool mechanic) he opened his own company. At the
beginning the company specialized in the production
of numbering mechanisms. In 2005 he opened a
second company in Croatia. Today the company has 135
employees in Germany and 30 in Croatia. They all have
one goal only: to be the best in the niche they are working in.
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HYPERION long life nozzles
No material can resist, no turn is too dif� cult. BARTON, the brand for innovative,
economical solutions for waterjet cutting, presents the HYPERION long life
nozzle. Exclusively supplied by CERATIZIT. Experience cutting perfection.
Barton Mines Company, LLC. www.barton.com Tel.: (800) 741-7756 E-mail: info@barton.com

Water cutting technology
Technology:
Cutting with a high power water jet has an ever increasing
number of application fields. The cutting principle
is based on a water jet focused by means of a nozzle
system and the production of extremely high pressure (up
to 4,000 bar). The focused water jet reaches a speed of
up to 2,950ft/sec. Depending upon the material which
has to be worked, the cutting operation is carried out with
pure water or by adding abrasive materials.
Advantages:
The components are cut at room temperature, i.e. no
thermal stress occurs. Only one ‘tool’, the water jet,
is applied for all materials. The forces are low so that
tension in the components is completely avoided.
Virtually all materials up to a thickness of 5.9" can be
worked without problems utilizing this technology:
metallic materials, stone and ceramic, plastic, composite
materials, sealing materials and even food. Cleanness is
one of the aspects that has to be pointed out in particular
as unlike thermal procedures this technology does not
produce any exhaust or other problematic emissions.
Industry sectors:
Water jet technology is mainly applied in the following
sectors: mechanical engineering in general, automotive
and aerospace industry, packaging industry, medical
systems and electrical industry.
The cutting head:
The cutting head is particularly significant for both the
result of the cutting operation and process security.
One of the key components is the focusing tube which
is decisive for the focusing capacity of the abrasive jet.
CERATIZIT has in-depth know-how regarding the development
and production of focusing tubes. (Picture: cutting
head with focusing tube)
CERATIZIT UltraMant focusing tubes
The “UltraMant“ brand is synonymous with carbide alloys
of utmost wear resistance. The requested cutting quality
remains consistent over a long period of application.
Close hole tolerances, perfect grinding and concentricity
are additional advantages of the CERATIZIT
focusing tube. CERATIZIT focusing tubes are suitable
WATER CUTTING TECHNOLOGy
for all modern cutting head systems and support automatic
centering when clamping the tube. A well-
structured warehouse guarantees quick delivery. Extensive
technical advice is a part of the service we offer to our
customers.
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’Cutting Tool’ Division
Business unit ’End users’
SECTOR / SEGMENT cutting tool solutions for...
Automotive crankshafts
motor units
brake systems
pumps / turbo chargers
running gears / power train
Energy and transport aerospace
railway vehicles
turbines
electric engines
Mechanical engineering roller bearings
machine manufacturers
rolls / bars
Oil industry tubes / couplings
Distribution partners turning / milling / parting and grooving /
drilling and boring
Business unit ’Tool manufacturers’
SECTOR / SEGMENT CERATIZIT specialities
Manufacturers of solid carbide and rods and blanks, sintered and ground,
brazed precision tools brazed inserts and inserts
Suppliers of inserts and tooling systems, standard and special inserts,
tooling systems precision-sintered or preground blanks

’Wear Part’ Division
Business unit ’Wood and stone’
SECTOR / SEGMENT CERATIZIT specialities
Wood and stone working saw tips, blanks, indexable knives,
inserts, drill tips,
rods (round, rectangular, with profile)
Writing instruments balls
Business unit ’Industrial wear parts’
SECTOR / SEGMENT CERATIZIT specialities
Paper, plastic and metal industry round, long and special knives
Medical systems blanks for dental instruments,
holders for surgical needles
Electronics, electrical engineering blanks for circuit board drills
Tool and mould making blanks for punching tools, blanks for powder compacting tools,
nozzles for plastic injection moulding
Metal forming technology dies for screw production, nail making tools,
drawing tools, hot rolls
Textile and tobacco industry sleeves, textile cutting parts, discs
Precision tool manufacturers blanks for circular knives, blanks for hobs
Automotive valves, injection pistons, sleeves, tappets
Special industry applications high-pressure tools, lock parts,
construction parts, recycling,
water-jet nozzles, seal rings
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<strong>stories</strong> on hard material matters
0464 EN|USA 01.08