stories on hard material matters - Ceratizit S.A.

01/08
<strong>stories</strong> on hard material matters
Product of the Year
MaxiMill 211 with HyperCoat coating for
economic milling - a game you will win!

Titanium machining with CERATIZIT
CERATIZIT engineers thoroughly studied the characteristics of titanium
and designed a machining solution for this material only.
The result is a perfect symbiosis of tungsten carbide, geometry and
coating expertise - a symbiosis titanium cannot resist.
www.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 exclu-
sive 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 wantto 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 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 doubledigit
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
A WORD
FROM THE BOARD
A WORD FROM THE BOARD
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.
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
“We prefer to be the number 1 in selected segments than the
number 3 overall”, says Board member Wolter.
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 fulfil 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

04
CONTENTS
03
06
07
08/09
10/11
12/13
15
16/17
18/21
22/23
24/25
26
27
28/29
30
31
32/33
34/35
36/37
38/41
42/43
A word from the Board
Thierry Wolter
Presentation
High Speed Machining
Plansee Seminar 2009
- from 25 to 29 May in Reutte, Austria
Trilogy on ship building
Aerodyn - machining of propelling screws
Trilogy on ship building
SCANA - machining of motor shafts
Trilogy on ship building
Outokumpu - machining of
stainless steel
MAC coolant set
Dry aluminium machining
Metaldyne India
Automotive machining
Audi Hungaria
Crankshaft machining
Leicht + Müller
Stamping technology
Hilti
Drill manufacturer
MaxiMill HEC
High Efficiency Cutting
Change in leadership
CERATIZIT Germany
MSS-SX
Blade system for parting and grooving
Coated CBN
World innovation from CERATIZIT
MaxiMill HFC
High Feed Cutting
Rado
Carbide watch cases
Zrinski Tehnologia
- has found the right tooling partner
Titanium machining of
the future - CTC5240
VM Motori, Italy
Manufacturer of Diesel engines
HPC 12
High Performance Cutting
1
2
3
1
2
imp:act 01/08

3
IMP:ACT 01/08
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
7 TH INTERNATIONAL CONFERENCE ON HIGH SPEED MACHINING
CERATIZIT at the 7 th International
Conference on High Speed
Machining
From 28 to 29 May 2008 in Darmstadt the renowned
international conference on the topic of high speed
machining took place at the brand new conference
centre ’Darmstadtium’. The impetus for the idea of
the main topic of this conference on high speed
machining (which is held every two years) came from
the American aerospace industry in 1975.
It was the first time then that significantly higher
cutting speeds were proposed for industrial applica-
tions in aluminium component machining. In this
context the following advantages were shown during
the first tests: improved surface qualities combined
with notably increased machining efficiency, reduced
cutting forces combined with a higher metal removal
rate, and enhanced precision of the components
thanks to better heat transfer into the swarf. In order
to achieve this, new machines had to be designed
which were able to operate with high-performance
spindles and high machine dynamics. Today such
high-speed processes enable five to ten times higher
cutting speeds than conventional processes in the
aerospace industry, are applied in the field of mould
and die construction and in the automotive industry.
The resulting demands on component geometry,
machine concept, machining strategy and tools have
been presented to and discussed by a large audience
in the framework of this international conference since
the 1990’s. In two days over 120 participants listened to
up-do-date presentations of the topics of process stabi-
lity, dry machining, machines and tools, simulation,
imp:act 01/08
modelling, spindle systems and hard machining, while
visiting the various booths. Obviously CERATIZIT could
not miss this occasion. Dr. Schleinkofer gave a presentation
on high-speed machining when using ceramic
materials, and in the exhibition area close by the visitors
could inform themselves about the competences
of the CERATIZIT group.
“A large expert audience consisting of machine
manufacturers, tool producers and operators were
provided with up-to-date information on all aspects of
high-speed machining. In particular the new methods
of machining process analysis (based on the machine,
the work piece and the tool) were extremely interesting.”
Dr. Uwe Schleinkofer
Dr. Uwe Schleinkofer, head of the cutting tool development department. CERATIZIT tools for high-speed machining.

PLANSEE organises the
17 th PLANSEE Seminar
from 25 to 29 May 2009 in Reutte, Austria
Scope of the Seminar
The presentations at the 17 th 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 17 th Plansee Seminar on Powder Metallurgical High
Performance Materials will take place at the head-
quarters 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 mate-
rials 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. At the same time, responsibility for our
PLANSEE SEMINAR 2009
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 conti-
nue 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 define 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
SHIP BUILDING TRILOGY 1/3 - AERODYN
Full speed ahead with cutting
inserts from CERATIZIT!
The Swedish shipbuilding company Aerodyn increases depth of cut
by 50 %, thus doubling tool life
From the left: Hans Axelsson (CERATIZIT sales manager Lars Andersson
(Aerodyn managing director), Petri Piippo and Chung To (both of them
Aerodyn employees) find the increase in productivity gratifying which
they have achieved together.
The Swedish company Aerodyn specialises in the
machining of blades for propelling screws. The cast skin is
eliminated and the profile finished through milling. After
milling the surfaces are carefully polished. In this way,
since the year 2000, several projects have been realized
in close cooperation with the carbide expert
CERATIZIT and productivity increased.
Propelling screw in application
The propelling screw converts the
energy produced by the motor
into motion. The propeller blades
are characterised by a hydrodynamic
wing profile. The blades
are designed in such a way that
the water streams around them
asymmetrically when they rotate. A
difference of pressure is caused in or
contrary to the direction of movement.
A current called `thrust´ is generated
and drives the vessel.
5-axis milling centres for propelling blades
Aerodyn was founded in 1989 and first produced
imp:act 01/08
Laser-aided: an Aerodyn employee measures the cast blade, and
determines the milling procedure.
components for the aerospace industry: this is where
the company name comes from. The company is
based in the Swedish Karlskoga and has 40 employees
who now specialise in the machining of propelling
screws. In this special field Aerodyn is one step ahead.
The secret: Aerodyn was one of the first companies to
utilize 5-axis machining centres for the machining of
this kind of blade. Previously, they used to be ground,
not milled.
Per year the Aerodyn employees machine between
500 and 700 blades and numerous other components
for propulsion systems of super oil tankers, freight
vessels and cruise liners. The blades, cast in bronze or
stainless steel, weigh between 80 kilos and 5 tons and
are shipped directly to the company which equips
the vessels with them. There they are assembled as
propelling screws. The cycle time of one blade at
Aerodyn ranges from two to three weeks or three
months, depending on its complexity and size. The
propelling screw has two to seven blades. Propelling
screws for ice-breaking vessels are normally made of
stainless steel. 75 % of Aerodyn’s blades are made of
bronze, the others of stainless steel.

Maximum quality requirements – surface quality is
decisive
Aerodyn’s quality requirements are extremely high. The
customers’ specifications concerning both strength
and form are very precise, in fact a surface roughness
of R a 1.6 is often demanded. Furthermore the weight
of the single propeller blades should not differ from
each other. With a given weight of the blades of 3.8
tons the tolerance is only 6 kilos, in a very fast vessel
the difference in weight must not exceed one kilo. For
every order independent audits are carried out before
the products are released.
Productivity increase with CERATIZIT tools
In recent years several projects in the field of cutting
tools have been realized in close cooperation between
SHIP BUILDING TRILOGY 1/3 - AERODYN
the Swedish Aerodyn sales and the CERATIZIT Energy
& Transport segment. The CERATIZIT inserts -M31 CTC
5235 with HyperCoat-coating have, for instance,
been applied now for several months. And the results
are stunning. “Applying the CTC5235 inserts we have
been able to increase the cutting depth by 50% and
simultaneously double tool life. I don’t think we need to
go into more detail here“, says a satisfied Petri Piippo,
production manager at Aerodyn.
Lars Andersson, Aerodyn managing director, on the
question about the particular advantages of working
together with CERATIZIT states: “Quality, service and
market-adapted prices are the characteristics of
CERATIZIT. We also appreciate the possibility to be able
to order online via the E-TechStore at CERATIZIT.”
The propeller blades are characterised by a hydrodynamic wing profile: blades weigh between 80 kilo and 5 tons. Propelling screws for ice-breaking
vessels are normally made of stainless steel.
09

SHIP BUILDING TRILOGY 2/3 - SCANA
Motor shafts on the high seas –
customer story from CERATIZIT
Scana relies on CERATIZIT’s competence in ship building
2No matter whether it is a tanker or a luxury cruise liner,
a motor yacht or a passenger ferry - all these vessels
have one thing in common: shafts transmit the force
from the engine to the propeller. The production
of such shafts is a speciality of the
Scana company. For turning ope-
rations, Scana relies on inserts and
tools from CERATIZIT.
10
Scana Björneborg in Sweden is
part of the Norwegian Scana
Industrier ASA, which manufactures
steel products for the
following five industry sectors:
energy (components for generators
and turbines), ship building
(propeller shafts and hubs),
machines and transport (axles,
clutches and forks for fork lifts), steel
(rolls, forged components and profiles)
and offshore products (valves and joints for drilling
platforms). The entire group has 1,850 employees, 320
at the Björneborg site.
Inserts for international customers
The Björneborg site looks back on a long forging
tradition: the first forge was built as far back as 1656.
Scana Björneborg has its own steelwork, its own forge
with a 3600/4500 ton press, a facility for heat treatment
and a machine hall for finishing. Per year about 2,500
For the turning of shafts (this one here is 25 metres long) Scana relies on
inserts and tools from CERATIZIT.
imp:act 01/08
products are manufactured for ABB, Siemens, Rolls
Royce, DEW, Wärtsilä, Metso and Shell. In the field of
turning Scana applies inserts and tools from CERATIZIT.
The roughing of a propeller shaft takes between 15 and 30 hours.

Interview with Magnus Dåverhög, production
and process engineer at Scana:
Which material are the shafts made of?
Dåverhög: “The shafts are made of steel. The alloy is
adapted to the application and requirements. Every
product we manufacture is therefore unique.”
Where do you buy the steel?
Dåverhög: “We buy steel scrap within a radius of 150
km and melt it ourselves. The waste produced at our
company during machining is also recycled. The raw
material department machines about 80,000 tons of
steel per year. We use 100 different steel grades.”
How much swarf is produced per month?
Dåverhög: “That depends on the parts we machine. On
average these are around 1000 tons per month.”
How long does it take on average to machine a shaft?
Dåverhög: “After forging the shafts are subject to heat
treatment and are then transported to the machine hall.
Most of the time the parts are only rough machined,
which takes between 15 and 30 hours. If the shaft has to
be finish-machined (as in the case of naval shafts) we
are talking about several hundred hours.”
What is so special about this kind of machining?
Dåverhög: “We produce shafts with a length up to 25
metres and a diameter of up to two metres. All shafts
are produced through open-die forging. As every shaft
is unique, their manufacture can be considered as a
SHIP BUILDING TRILOGY 2/3 - SCANA
Magnus Dåverhög, production and process engineer at Scana.
special art. It takes many years to train a good machine
operator so that he is able to carry out turning and
milling operations reliably. We are therefore very happy
to have more than 350 years of experience at the
Björneborg site!”
How do you assess the relationship of Scana and
CERATIZIT?
Dåverhög: “We strive continuously to optimize our
processes. In this respect the tools in the workshop are
an important element. We work together very closely
with some companies, and CERATIZIT is one of them.
CERATIZIT always provides tools which correspond to the
state of the art of carbide technology.”
Scana Björneborg has wide experience in the manufacture of long products. The first forge was built as far back as 1656.
11

12
SHIP BUILDING TRILOGY 3/3 - OUTOKUMPU
Building bridges in the world with
CERATIZIT
Carbide expert CERATIZIT helps with the machining of stainless steel
for giant tankers and bridges
Stainless steel is a material which is difficult to machine.
It is characterized by low thermal conductivity and a
relatively high tendency to cold hardening; it is tough
and tends to adhesion. The consequence: its machinability
is four times worse than the one of machining
steel. A big challenge, as shown by the example of the
CERATIZIT customer Outokumpu in Degerfors in Sweden.
Stainless steels are very popular thanks to their particular
properties. The material has an aesthetic appearance,
is resistant to corrosion and can be recycled completely.
It is mainly applied in the fields of catering and
household (33%), construction of industrial plants (26%)
and transport (16%). Stainless steel consists of at least
10.5% to 13 % of chrome. Thanks to this high chrome
content, a protective passive layer of chrome oxide
is created on the work piece surface. Stainless steel is
mainly used in sectors where cleanliness and hygiene
are of utmost importance. In fact this steel is resistant to
water, vapour, humidity, salt, acids in food and weak
organic or inorganic acids.
Know-how for high-tech bridge construction
The Outokumpu group achieves a turnover of six billion
euros with 8,000 employees worldwide. The vision of the
group is to become the uncontested number 1 in the
stainless steel sector.
3
The Outokumpu plant in Degerfors mainly
manufactures stainless steel flat and
long products. “We have a very
wide product range and countless
applications are possible”, says
Business Development Manager
Anders Finnås. One of our
speciality fields is ship and bridge
building. The company produces
sheet metal for the internal
panelling of tankers which transport
chemical products. In the field
of high-tech bridge construction the
company‘s know-how lies primarily in
the production of sheet metal and structural
parts made of stainless steel. “Both appearance
and corrosion resistance play a very important
role. A bridge in stainless steel is not only technically
interesting but also has a longer service life, and is also
visually appealing thanks to the material,“ says Finnås.
A prestige project in Hong Kong: Stonecutters Bridge.
An Outokumpu employee checks the milling cutters.
imp:act 01/08
Stonecutters Bridge in the Hong Kong harbour: a
prestige project
In Hong Kong at the moment one of the longest cablestayed
bridges in the world is being built: Stonecutters
Bridge. From 2009 onwards this highway bridge will relieve
the city centre of container trucks and serve as a prominent
gateway to the harbour of the city. The bridge’s
structural system will have a width of 51 m and will be
provided with 4 lanes in every direction plus a breakdown
lane. The total length of the bridge will amount to
1596 metres with a span of 1018 metres.

Due to the saline air and the strong gale-force winds in
Hong Kong the upper 120 metres of the 300 metres high
bridge pylons were cladded with high-tensile stainless
steel (duplex) by Outokumpu. The company produced
both the cladding elements made of stainless steel (all
in all 2,000 tons) and the anchoring of the main bearer
cables. What is so special about it? The duplex stainless
steel will need no maintenance work for the entire
service life of the bridge.
More than only stainless steel sheets
Outokumpu however does not only supply stainless steel
sheets. The company supports customers with regard to
material selection, planning and construction during the
entire project and optimally prepares the sheet metal
with perfect surface treatment, precise form and joints
tailored to the welders’ needs.
High demands with regard to the CERATIZIT inserts
The CERATIZIT cutting inserts are used at Outokumpu
for the preparation of joints. With the HyperCoat grade
CTP2235 Outokumpu mills the most varied joint profiles.
Stainless steel is a material which is difficult to machine.
Internal cladding in stainless steel in a tanker that transports chemical materials.
SHIP BUILDING TRILOGY 3/3 - OUTOKUMPU
For example, its thermal conductivity is only a third of the
thermal conductivity of machining steel. For this reason
the heat that is produced during machining can only be
evacuated insufficiently through the swarf. The tendency
towards work hardening is relatively high. This means
that after a first machining step the material on the
surface becomes harder than before, so the cutting edge
needs to perform even better in the second operation.
Furthermore, stainless steel is particularly tough, has a
relatively high tendency to adhesion and bad chip
formation. This is why its machinability is four times
worse than the one of machining steel. Especially for
Outokumpu CERATIZIT has developed the cutting
insert SEAN250161 and offers a tailored solution for the
machining of stainless steel. The inserts are used in a strip
edge milling cutter by Outokumpu. In this way the ideal
tool is created for the machining of difficult materials
such as stainless steel. Good clamping, small tool overhang
and small corner radius or radius of the cutting
edge are decisive to avoid vibration and cutting forces.
Sufficient cutting depth should be applied so that the
cutting edges in the following operation interact as little as
possible with the cold formed layer.
13

MaxiMill 211 – make the connection!
1: Win with performance, 2: Win on quality,
3: Win time savings, 4: Win tool life.
MaxiMill 211 with HyperCoat coating for economic milling -
a game you will win!

World innovation: machining of
aluminium wheels now
without coolant
Benefit from savings with the new MAC tool from CERATIZIT
One of the special fields of the carbide expert CERATIZIT
is aluminium wheel machining. The recently developed
MAC system 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 aluminium 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 20 cent per kilo or approximately one
euro per wheel. For tens of thousands of aluminium rims
where dry machining is applied instead of wet machining
attractive saving is realized very quickly. With the latest
world innovation MAC from CERATIZIT, aluminium rim
producers can save money, optimize their profit and
distinguish themselves from competitors.
Ingenious: MAC cools utilizing the Joule-Thomson effect
“There were already various external air cooling
systems available in the market, however, their effect was
satisfactory 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 tool 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 imme-
diately 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
sub-zero range and efficiently cools both work piece
and tool. About 6 bar and 400 l/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 aluminium.
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 programme for dry machining
Currently the following grades are available for dry
machining of aluminium 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 aluminium 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 aluminium alloys with
increased silicon content (Si ≥ 12 %), for polish turning of
mirror faces and the machining of high-quality wheels
and components in aluminium.
The newly developed MAC system from CERATIZIT now allows the
complete dry machining of wheels without refitting machines.
15

16
METALDYNE, INDIA
CERATIZIT customer
report at subcontractor
Metaldyne in India
Metaldyne Managing Director Sabherwal:
“CERATIZIT does not sell bulk products, but engineering”
“Metaldyne believes in the strength of people and
ideas”, Tim Leuliette, chairman of the Metaldyne Board
describes the mainspring that drives the company.
Metaldyne is a leading global designer and supplier
of power train and chassis products for the automotive
industry. Metaldyne has been a CERATIZIT India
customer since 2003.
Metaldyne supplies brands such as Ford, Honda, Renault,
Nissan, Toyota and Daimler-Chrysler with high-quality
products. The company has 6500 employees worldwide
and achieves a turnover exceeding 2 billion dollars. The
products range from dampers, exhaust parts, pumps
and assemblies for clutches and differential gears to
suspension components.
Flywheels for trucks and dampers for cars
The Metaldyne site in Jamshedpur, India, employs 330
people. Here flywheels for trucks and dampers for cars
are produced. The products arrive as cast iron compo-
nents and are then machined with CERATIZIT tools. Per
month around 4,500 flywheels are manufactured by
Metaldyne. It takes 13 minutes to machine a flywheel.
With a cutting edge of the CERATIZIT turning insert
CNMG120408/12EN TFQ in the grade CTC1110,
Metaldyne machines up to 30 flywheels.
Metaldyne Jamshedpur produces about 25,000 ’dampo-
lators’. A ‘dampolator’ is a ring which reduces vibration
of the crankshaft when machining at high or also low
RPM. Six machining operations are necessary until a
blank is finished. For this purpose the CERATIZIT inserts
CTC11353 and CTC1125 are applied. A damper is
completely machined within only four minutes. This short
machining time can only be achieved because tool life
is relatively long. One cutting edge (CTC1125) can be
used to face turn up to 270 parts and a cutting edge of
CTC1135 does the finish turning for 90 components until
it has to be reversed.
Metaldyne employee balancing a flywheel.
imp:act 01/08
After the flywheel has been machined the external ring is mounted.

Interview with
Sanjay Sabherwal,
Managing Director
Metaldyne India
Mr. Sabherwal, what is most typical of the Indian
industry?
Sabherwal: “I would say the speed, definitely. In 1991
it took about three weeks to get a telephone installed,
now there are approximately six million new telephone
contracts per month. This is why India has a telecommunications
system which is far more modern than, for
example, the American system. Mobility is also increasing
rapidly: We have so many airline flights now that
we cannot train enough pilots – we employ them from
other countries.”
The automotive industry is booming in India. An example
is Tata presenting its new small-sized and low-budget
car called the `Nano´. What does this mean for the
suppliers to the automotive industry such as Metaldyne?
Sabherwal: “For us this means an incredible price pressure.
Cost reduction is an ongoing process in this industry,
translated into as many parts per minute as possible.
Today the production volumes are about 1.4 million cars
and 500,000 trucks per year. These numbers require a
different approach in production.”
Damper parts for automobile motors before machining.
Sanjay Sabherwal, Managing Director.
METALDYNE, INDIA
What about quality?
Sabherwal: “Quality is taken for granted. Customers are
more interested in process stability and reliability.”
CERATIZIT is your preferred partner for cutting tool
solutions. Why is CERATIZIT different?
Sabherwal: “CERATIZIT does not sell a commodity, it sells
engineering, and this is what we need. Our customers pay
for designed products with added value, so we design
for our customers. CERATIZIT offers great solutions which
enable the highest speeds with the best feeds at the
lowest prices! Another plus for CERATIZIT is the enormous
commitment to our company, which is the basis of a
healthy relationship.”
17

18
CRANKSHAFT MACHINING AT AUDI HUNGARIA
Crankshaft machining
with tailor-made inserts
from CERATIZIT
Report from the CERATIZIT customer Audi Hungaria
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 manufactured.
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
technological leader in the field of carbide for wear parts
and cutting tools.
Crankshaft machining at Audi
Györ is situated 45 km 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 50 km
there are competitive subcontractors, a hall with a
surface of 100,000 sq.m. already existed, and a lot of
people in this area speak German very well. Furthermore
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.
imp:act 01/08
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 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 26
kg, after machining it still weighs as much as 18 kg.“
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 26 kg, after
machining it still weighs as much as 18 kg.

Three highly modern complete automated production lines in the huge 100,000 sq.m. 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 BEI AUDI UNGARN
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.”
19

20
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 opti-
mized. 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 years
Patrick Zobl, product manager at CERATIZIT,
describes crankshaft machining in detail
Technique for crankshaft machining
• High cutting speeds (up to 260 m/min)
• Planetary milling cutters with diameters ranging from
350mm to 750mm
• 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.
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 centring
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
21

22
LEICHT + 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, telecommunication,
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.
Some of the Leicht + Müller products: around a billion
of such parts are produced per year.
As far back as 1985 Leicht + Müller also started their
production 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 5,500 sq.m.
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 considering
the high acquisition costs and the extraordinary
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 compo-
nents (plastic-metal composite material).
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 + 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).
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.
23

24
HILTI, DRILL MANUFACTURER
CERATIZIT produces carbide
bits for HILTI drills
Customer story for 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 Liechten-
stein. 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
2
1
imp:act 01/08
On the interface between the drill and the base material the carbide
from CERATIZIT shows its strength, ensuring long tool life.
CERATIZIT Luxembourg. The solid head solution of the
HILTI drill is still unique today. There are no single carbide
pins 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 produc-
tion 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 brittleness 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
Solid head drill with gradient zones in C3X geometry, 4-16 mm – the best
powder-metallurgical development at the EPMA conference.
Carbide with a gradient structure: 1 Wear resistant on the
drill tip, 2 Stable welded connection with the steel shank

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 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 Consum-
ables 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.”
HILTI, DRILL MANUFACTURER
focuses on high quality. Dr. Cramer says: “In addition
to drills HILTI also 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
5 mm (length 120 mm) up to diameter 40 mm (length
920 mm).
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.
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 HILTI drills with CERATIZIT carbide bits are supplied throughout the world.
25

26
MaxiMill HEC
CERATIZIT‘s MaxiMill HEC offers
clear performance advantages:
High Efficiency Cutting
The new MaxiMill HEC cutters from CERATIZIT will reduce tooling costs when machining Cast Iron components and maximise productivity.
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 enduser.
Typical application areas for MaxiMill HEC would
be cast iron components such as contact faces of
crank cases, cylinder heads, turbochargers and pump
cases, etc.
imp:act 01/08
“MaxiMill HEC is the result of an ongoing and extensive
development programme 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 maximise 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 200m/min, 0.25 mm/tooth
feed rate with up to 5 mm depth of cut and 79 mm
width of cut. Similarly, GGG 70 material at a hardness
of HB 240-300 can be cut at 180 m/min at a feed
of 0.2 mm/tooth.

Change in leadership at
CERATIZIT Germany
CHANGE IN LEADERSHIP AT CERATIZIT GERMANY
Jan van der Veen leaving – Andreas Olthoff taking over
“Now it is important to find one’s own way to follow
in the footsteps of a great predecessor.” This is how
Andreas Olthoff, new managing director of the CERATIZIT
Deutschland GmbH, sees his task. At the beginning of
August he followed Jan van der Veen who retired after
fifteen years at CERATIZIT.
“I believe that a company cannot be successful without
team spirit“, says Andreas Olthoff, new head of CERATIZIT
Deutschland GmbH. He sees his style of management as
‘result-oriented’ while allowing employees a good deal
of individual responsibility.
A rapid career
The new managing director (age 41) has already
gathered experience at the German branch of an
American company. He began his career in the field of
sales there after studying mechanical and economic
engineering. He became key-account manager for
northern Europe, subsequently sales manager and was
then appointed managing director.
“After fifteen years I was looking for a new professional
challenge,“ he states. At CERATIZIT Germany he
accepted this challenge. The sales volume of the
CERATIZIT group in Germany is 100 million Euros; the
sales company employs 65 people. The new managing
director says: “I’m happy to have found a growing
company with an excellent international position. It is
a gratifying and challenging task to contribute to the
further success of CERATIZIT.”
Commitment to the Corporate Values
Andreas Olthoff considers Corporate Values an overall
concept with important functions. He thinks that the
value of communication and an interaction based on
trust between superior and team are essential for a
continuously growing company. “No company can be
successful without the active implementation and experiencing
of values,” he says. “I would like make a contribution
to this company culture.”
His predecessor Jan van der Veen supports this belief: “I
have often regretted that we talk a lot about our corporate
values but do not always live according to them.
Communication matters, trust and respect matter!“
So the change of generations at the vanguard of the
CERATIZIT Deutschland GmbH is all settled.
Takes over the leadership of the brand: the new managing director
of CERATIZIT Deutschland Gmbh, Andreas Olthoff (left) with his
predecessor Jan van der Veen.
Short description of Andreas Olthoff
Age 41, married
Hobbies: running (marathon), squash, motor-biking
Studies: mechanical and economic engineering
Professional career:
• 15 years in the German branch of an American
company (listed on the stock market) selling
hydraulic tools. His positions were
• Junior sales representative
• Key-account manager for northern Europe
• Sales manager
• Managing Director
27

28
MSS-SX
imp:act 01/08

MSS-SX
MSS-SX
blade system
for parting and
grooving offers
distinct
advantages
The latest parting and grooving innovation from Ceratizit
provides users with a much simplified operating procedure
that ensures precise insert location and expedites
the setting process.
MSS-SX features an innovative clamping system that
allows inserts to be locked into position, using the
supplied tool, from either side of the blade, making it
suitable for a variety of machine tool configurations. This
tool is located in the two location points and is used,
initially, to open the insert seat prior to the insert being
positioned. The reverse movement of the tool then causes
the seat to clamp the insert precisely and securely.
In creating the insert pocket for the MSS-SX system,
Ceratizit employed finite element analysis to ensure the
optimum insert seat and clamping system was created.
The result is a guarantee of perfect insert seating every
time, along with consistent positioning of the insert to
eliminate time-consuming adjustments after an insert
is changed. Furthermore, the retaining system ensures
good insert security under the most arduous of cutting
conditions. It can be applied for parting, grooving and
longitudinal turning.
Simple and accurate adjusting of the cut length
The final outcome is a parting and grooving system that
provides functionality and handling but with maximum
stability under difficult cutting conditions. This functionality is
enhanced by the addition of laser-etched scaling
applied to the cutter blade, which makes adjusting of the
cut length simple and accurate. “This visual and indelible
mark provides an easy reference for the user,” says Vince
Kelly, Ceratizit’s Managing Director. “While the use of
the blade toolholder system significantly increases the
application range of the MSS-SX, without losing any
efficiency, strength or precision.”
29

30
COATED CBN
CERATIZIT successfully applies
CBN with HyperCoat coating
Tool life increased between 30 and 40 % compared to uncoated CBN
With the HyperCoat grade CTL3215 CERATIZIT will for the
fi rst time present a coated CBN (cubic boron nitride)
material. 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 metres per minute, depending on the
application. The tooling solution therefore requires stable
machining conditions and is applied without cooling
lubricant. Tool life compared to uncoated CBN is
increased between 30 and 40 %.
CERATIZIT supplies the most important producer of CBN
materials with the tools necessary for high-pressure
synthesis (anvils and dies). Furthermore CERATIZIT has
been selling CBN inserts for many years, and to an
increasing degree also tools for milling applications.
The stress the tools are subjected to during these milling
operations is caused by interrupted cut, thermal shock
and oxidation, and represents one of the threshold
applications of CBN. The carbide expert CERATIZIT has
faced this problem by providing CBN with the functional
HyperCoat coating and using it for milling applications,
which considerably enhances both process security
and tool life. In addition it has become clear that these
improvements are also achieved in turning applications
under diffi cult conditions, such as the machining of grey
cast iron and chilled castings.
imp:act 01/08
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.
Cutting material with success story
CBN has been known as a cutting material for almost
40 years. 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 materials. 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. It 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.

MaxiMill HFC
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
HyperCoat 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 guarantee maximum performance in terms
of tool life, surface quality and reduced tendency for
vibration.
The optimised 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 3.0 mm
per tooth), plunging for the production of deep pockets
and with maximum chip removal rates (more than
1,500 ccm/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.
31

32
RADO, CARBIDE WATCH CASES
Exclusive watches in classic
carbide from CERATIZIT
The Swiss watch manufacturer Rado relies on scratchproof
cases from CERATIZIT
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 manu-
facturer 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 centres 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
Carbide case from CERATIZIT for the Swiss watch manufacturer Rado:
injection moulded parts before sintering.
imp:act 01/08
scratches in sapphire, sapphire in glass, and glass in metal.
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 jewellery 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 fulfil 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 industrial 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 mit Peter Oppliger, Purchasing Manager Rado
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 moulding. 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 moulding 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 manu-
facture 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 optimise 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.”
33

34
ZRINSKI, CROATIA
Aluminium component.
A ZRINSKI employee checking the quality of an
aluminium 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 installation. Using aluminium, 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. Produc-
tion 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.”
“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
aluminium machining. Domislović: “We are really delighted
with the cutting tools for titanium machining. When
machining a titanium work piece (3.7164, Ø21 x 165mm)
with a CERATIZIT solution we machine 130 parts per
cutting edge, which means twice as much as with the

Cutting tools for medical systems: ZRINSKI produces titanium implants
with tools from CERATIZIT.
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.”
From tool mechanic to entrepreneur
Josef Zrinski, born in Croatia, moved to Germany at the
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.
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.
35

36
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 fibre. In this context
titanium is also gaining ever more importance in aircraft
construction. In fact structural components which hold
the carbon fibre 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 aluminium are
reducing in importance. Consequently 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 re
sistance 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 aluminium. Simultaneously they show twice
as high a strength so that structural components can
be designed slimmer and with lower weight. A disad-
vantage 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 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.

Oliver Baum, Product Manager Aerospace.
TITANIUM MACHINING
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 15-20% 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. In order to minimise 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 fulfils these specifications.
The inserts for titanium machining are customarily
provided with protective chamfers in order to stabilise
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.
Compressed chips due to insufficient chip formation
vs. spiral swarf.
37

38
VM MOTORI, ITALY
Success story: two companies
in the same league
VM Motori produces Diesel engines applying know-how
and tools from CERATIZIT
Emilia Romagna - the country of Italian car freaks
VM Motori, founded by the entrepreneurs Vancini and
Martelli in the year 1947, specializes in the manufacture of
Diesel engines. At the beginning the engines were exclu-
sively applied in agricultural machines and ship
building as well as in general industry. Later, however,
they were also used in automobiles thanks to an innovative
generation of engines provided with a super-
charger system as a standard feature. In 1990 VM
launched the Turbotronic engine which through its
electronic control of the combusti on process
and the recycling of the exhaust gases guarantees
high performance combined with minimum
pollutant rates. Turbotronic was a revolutionary engine,
the cleanest of its class, that was mounted for more than
ten years in cars produced by General Motors, Ford and
Rover.
VM Motori is located in Cento, a town in the Italian region
Emilia Romagna. Enzo Casanova, Head of Manufac-
turing Engineering: “We live here in engine country. Our
area is known around the globe for its know-how in the
field of engine construction. Not for nothing are the firms
Ducati, Ferrari, Lamborghini and Maserati based here.
The people here love cars.”
Main topic: efficiency
Casanova: “VM Motori operates in a niche market
which is appropriate for our production capacity,
and allows our company to extend our know-how,
simultaneously improving our position as a professional
supplier and optimizing our competitiveness in the smaller
Diesel car segment. All suppliers - even those who were
against the use of Diesel fuel – had to deal with these
business segments as they were aware that it would be
difficult, uneconomic and slow to build and produce a
Diesel engine themselves. VM’s market position in fact
results from the capability to produce small quantities of
reliable and durable engines at competitive prices. In
addition, every engine must conform to the latest environ-
mental standards for the relevant market.
We consider ourselves the ‘tailors’ of the automotive
industry in order to underline VM‘s capacity to meet the
customers’ demands offering engineering, research &
development, production and tests.”
imp:act 01/08

In one word: flexibility
“The automotive industry demands ‘just-in-time’ produc-
tion from us,“ explains Casanova. “Neither we nor
our customers have a warehouse for engines. These
specifications force us to remain flexible.” Such flexibility
requires maximum efficiency: at VM Motori every step
has to be spot on.
Efficiency in production and in the product itself.
Diesel engines have always been very efficient: at low
revolution speeds they deliver higher torque than petrol
engines. A Diesel engine has a quicker response, and
thus a more direct acceleration. In addition there is the
VM MOTORI, ITALY
enormous advantage of very low fuel consumption. The
search for ways to further increase efficiency however
also continues in the field of Diesel engines. Diesel
engines are the heaviest engines available in the market.
Casanova states: “We are striving to reduce the weight
of our new V6 engine by applying compacted graphite
iron (CGI). Thanks to the mechanical properties of this
material we are able to produce parts with thinner walls
than would be needed for conventional grey cast iron.
Furthermore we produce camshafts from thick-walled
tubes. The cams are mounted on the tubes. In this way
we are not only able to obtain a reduction in terms of
weight but also of machining time.”

40
VM MOTORI, ITALY
Original and surprising developments are much
appreciated
VM Motori and CERATIZIT have been business partners
for a long time and have clocked up numerous
successes. “The HEC-11 system from CERATIZIT, for
instance, has been a great success“, says Claudio
Grisetti, production engineer at VM Motori. “We are
talking about a solution here which brought in a lot of
cash. After the first successful tests we integrated the
system into the ‘crankshaft’ production line.” Casanova:
“The milling cutters have shown advantages such as
reduced cutting forces which have increased tool life.
The geometry of the inserts has enabled a cost reduction
of 20% compared to the previous solution - we like being
convinced in this way!”
“The HEC11 system applied at VM Motori combines a
close pitch with eight usable cutting edges and high
process security through stable tangential inserts. The
system operates with minimum cutting forces, thus
reducing both deformation of the components and
vibration“, says Jürgen Duwe, research & development
department, CERATIZIT Austria.
Giovanni Pante, Key Account Manager Cutting Tools,
CERATIZIT Italia explains: “The essential thing when
attending to the needs of key account customers is
being able to listen and to fulfil their demands. The
customer tells us what he needs, while we help him to
come to an appropriate solution. Developing products
autonomously hoping that they will sell in the market is
just not an option.”
Casanova also confirms that it is not sufficient to offer
standard solutions. “We receive input from our business
partners that induces us to find solutions and procedures
which would not have occurred to us without them. We
want our business partners not only to fulfil our wishes but
to simply surprise us. This is how a business relationship
based on trust is created.”
VM Motori Diesel engines before the quality test.
imp:act 01/08
Claudia Grisetti (VM Motori), Pasquale Cristallo e Jürgen Duwe (both
from CERATIZIT) talking about new developments.
The weight of an engine for an automobile is between 240 and 280 kg.

Interview with Enzo Casanova
Head of Manufacturing Engineering at VM Motori
CERATIZIT: What are the trends in the engine industry?
Casanova: “There are very clear trends towards increased
efficiency and improved performance. An engine
with 150 hp can almost be considered a standard
engine and does by no means represent an exception.
Another tendency is towards engines with smaller
capacity (e.g. 1.5 litres) but high performance.
There is a strong tendency towards the construction of
engines with low fuel consumption which meet the ever
stricter laws on exhaust gases. It is a tough job to take all
these factors into account. The electronics of the engine
are therefore gaining importance as the potential in this
sector is still enormous.”
CERATIZIT: Why did you choose CERATIZIT?
Casanova: “After having looked at some prototypes
we decided to start a test phase with CERATIZIT
products which were not available in batch production
at the time. We firmly believed in the technological and
human potential of CERATIZIT. Now, some months after
the tests, we can say that the performance has more
than confirmed our choice.”
CERATIZIT: What are the misconceptions in the engine
sector?
Casanova: “There are two subjects which come to mind.
First of all, it is often said that Diesel engines are rather
loud and do not run smoothly. This is not really true. In
fact the noise level of an engine depends on the way
it is mounted in the car, i.e. how much vibration is transferred
to the body and how well it has been insulated.
Another misconception is that Diesel engines are big
pollutants. Here it must be said that the Diesel engine
has undergone a change: it now has lots of power and,
thanks to innovative technologies, at the same time it is
relatively clean (e.g. Diesel particulate filters).”
CERATIZIT: What are the test procedures for engines at
VM Motori?
Casanova: “All engines run for a few minutes in the
lab in order to check their performance and a certain
percentage of them is subjected to a stricter reliability
test. In the near future a ‘cold test’ will also be introduced
where the engine runs without consuming fuel, thus
making the tests more environmental-friendly.”
CERATIZIT: Can you give us some basic data on the
Diesel engine and its manufacture?
Casanova: “The weight of an automobile engine can
VM MOTORI, ITALY
Enzo Casanova, Head of Manufacturing Engineering at VM Motori.
be between 240 and 280 kilos. The engine itself consists
of 460 components including small parts such as screws,
clamping pins etc. The assembly of an engine takes
between two and three hours. The guaranteed performance
depends on the type of engine and on average
this lasts for about 200,000 kilometres.”
CERATIZIT: How strict are the specifications of the
automotive manufacturers?
Casanova: “The automotive industry requires that
numerous quality assurance measures are carried out
as well as procedures assuring repeatability in batch
production. Some of these are quality systems like
QS9000 or ISO TS16949. In addition there are customer-
specific requirements to ensure that determined
specifications are met.”
CERATIZIT: And what does this mean for a company like
VM Motori?
Casanova: “Our customers do not only demand that
we build and deliver high-performance engines,
but also set up a fully-fledged quality assurance
programme. Qualified employees have to be able to
provide the customer with detailed reports which in case of
problems give an immediate remedy and have to
prove at any time the quality of the batch production
process. It has to be guaranteed to the customer that
everything possible is being done to not only guarantee
the product’s quality by analyzing its possible defects
but also through preventive maintenance of all production
plants. Already some eight or nine months before
production starts the customer requires in addition that
the production capacity is proved with plants operating
at full load, which of course has effects on investments.”
41

42
HPC 12
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
aluminium 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 aluminium 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 aluminium 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 = 0.1 mm
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
aluminium 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 aluminium 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 = 4,712 m /min
• n = 15,000 rev./min
• f = 25,200 mm/min
• fz = 0.14mm
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.
Jürgen Duwe from the development department in the
HPC 12
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.”
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<strong>stories</strong> on hard material matters
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