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Profilemaster -;
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Profi leMaster –<br />
has totally redefi ned the machining process
2<br />
Headquarters and main site<br />
Mamer / Luxembourg<br />
With expertise and highly flexible<br />
production facilities we<br />
strive to provide our business<br />
partners with direct<br />
competitive advantages in<br />
the field of hard materials for<br />
tooling solutions and wear parts.<br />
Our dedication to hard material<br />
matters creates intelligent solutions<br />
for tomorrow and time to<br />
come. With 13 production plants<br />
North America<br />
• USA<br />
CERATIZIT – a global partner<br />
for advanced hard material<br />
South America<br />
• Brasil<br />
Direct sales and distribution partners<br />
Europe<br />
• Austria<br />
• Bulgaria<br />
• Czech Republic<br />
• France<br />
• Germany<br />
• Hungary<br />
• Italy<br />
• Luxembourg<br />
• Netherlands<br />
• Poland<br />
• Switzerland<br />
• Spain<br />
• United Kingdom<br />
Main site Reutte / Austria<br />
in the three main economic<br />
areas and a worldwide sales<br />
network of over 30 subsidiaries<br />
and distribution partners ensure<br />
a quick response to customer<br />
needs. In-house trainings and<br />
seminars guarantee that both<br />
business partners and employees<br />
share the latest information<br />
on our product range.<br />
The demand to improve the rela-<br />
tionship with our business partners<br />
results furthermore in long-term<br />
investments to strengthen<br />
the sales organisations in the<br />
various countries.<br />
The CERATIZIT corporate value<br />
‘The views and focus of our<br />
business partners matters’ is<br />
a guiding principle for all 3,500<br />
CERATIZIT employees worldwide.<br />
Asia<br />
• China<br />
• India<br />
• Japan
Machining of complex turned parts<br />
Which tools would you use to machine<br />
these workpieces?<br />
3
Machining with ProfileMaster<br />
ProfileMaster from CERATIZIT provides the comprehensive solution<br />
Right-hand tool<br />
Right-hand tool<br />
Right-hand insert<br />
Left-hand insert Right-hand insert<br />
Left-hand tool Right-hand tool<br />
Right-hand insert<br />
5
6<br />
ProfileMaster<br />
Machining methods<br />
Machining methods – radial application<br />
1<br />
2<br />
Machining methods – axial application<br />
3<br />
4<br />
5<br />
6<br />
7<br />
1<br />
2<br />
3<br />
4<br />
5<br />
Drilling into solid material with flat bottom holes<br />
Boring applications<br />
External turning applications<br />
Internal turning applications<br />
Turning of face profiles<br />
External radial grooving<br />
Internal radial grooving<br />
External turning applications<br />
Internal turning applications<br />
Turning of face profiles<br />
External axial grooving<br />
Internal axial grooving<br />
When changing from internal to external<br />
machining, reverse direction of rotation
“Masterfi nish”<br />
wiper effect<br />
– Excellent surface quality<br />
– Shorter machining times<br />
Considerable tool<br />
acquisition cost<br />
savings<br />
ProfileMaster<br />
Benefits<br />
Reduction of<br />
– Tool changing times<br />
– Reduced pre-setting and set-up times<br />
– Less programming effort<br />
Problem solver for<br />
insuffi cient tool<br />
storage capacity<br />
Reduced<br />
stock-keeping<br />
costs<br />
Variable<br />
drilling diameter<br />
Produces a fl at<br />
bottom hole<br />
7
8<br />
+30%<br />
-1%<br />
ProfileMaster<br />
Productivity<br />
Turn the cost screw together with CERATIZIT<br />
Tooling costs<br />
2 - 6 %<br />
Material costs<br />
14 - 18 %<br />
Increase in productivity:<br />
(parts produced<br />
per time unit)<br />
Due to improved utilization of the available<br />
machine capacity considerable cost reduction<br />
per workpiece becomes possible.<br />
In this context ProfileMaster from CERATIZIT<br />
makes a decisive contribution through:<br />
- fewer tool changes<br />
- increase of cutting speed<br />
- increase of feed rate<br />
- increase of depth of cut<br />
Break-down of workpiece costs<br />
Increase of<br />
tool life by<br />
+30%<br />
results in<br />
reduction of<br />
workpiece costs by<br />
-1%<br />
Increase in<br />
productivity by<br />
+30%<br />
results in<br />
reduction of<br />
workpiece costs by<br />
-19%<br />
Increase of tool life:<br />
Manufacturing costs<br />
(machine / manpower)<br />
78 - 82 %<br />
+30%<br />
-19%<br />
As the average tool costs amount to only<br />
2–6 % of the workpiece costs, prolonging<br />
tool life typically can only reduce total<br />
costs minimally.
Tools<br />
Inserts<br />
ProfileMaster<br />
Nominal diameter [mm]<br />
Cutting direction<br />
ProfileMaster<br />
ProfileMaster<br />
Designation systems<br />
Nominal diameter [mm]<br />
Cutting direction<br />
PM 25 R - 2.25D - E<br />
Version<br />
Cutting width [ mm / 10]<br />
Cutting depth [ mm / 10]<br />
PM 25 R G 35 30 04 - M20 CTC1435<br />
Corner radius<br />
Max. drilling depth<br />
Chip groove<br />
Carbide grade<br />
9
10<br />
1.5D (=l 2 )<br />
2.25D (=l 2 )<br />
Type,<br />
description<br />
ProfileMaster Ø .394-.630 inch<br />
L<br />
Tools / radial application<br />
inch<br />
D<br />
(mm) d 1 d 2 l 1 l 2 l 3 f A<br />
PM 10R-1.5D-E<br />
PM 10R-2.25D-E<br />
R<br />
(10)<br />
.394<br />
.500<br />
-<br />
.630<br />
3.150<br />
2.821<br />
.590<br />
.886<br />
-<br />
1.197<br />
PM 10L-1.5D-E<br />
PM 10L-2.25D-E<br />
L<br />
(10)<br />
.394<br />
.500<br />
-<br />
.630<br />
3.150<br />
2.821<br />
.590<br />
.886<br />
-<br />
1.197<br />
PM 12R-1.5D-E<br />
PM 12R-2.25D-E<br />
R<br />
(12)<br />
.472<br />
.625<br />
-<br />
.787<br />
3.543<br />
3.049<br />
.709<br />
1.063<br />
-<br />
1.299<br />
PM 12L-1.5D-E<br />
PM 12L-2.25D-E<br />
L<br />
(12)<br />
.472<br />
.625<br />
-<br />
.787<br />
3.543<br />
3.049<br />
.709<br />
1.063<br />
-<br />
1.299<br />
PM 16R-1.5D-E<br />
PM 16R-2.25D-E<br />
R<br />
(16)<br />
.630<br />
.750<br />
-<br />
.984<br />
4.921<br />
3.832<br />
.945<br />
1.417<br />
-<br />
1.831<br />
PM 16L-1.5D-E<br />
PM 16L-2.25D-E<br />
L<br />
(16)<br />
.630<br />
.750<br />
-<br />
.984<br />
4.921<br />
3.832<br />
.945<br />
1.417<br />
-<br />
1.831<br />
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts<br />
Ordering example: 3 pieces PM 16R-2.25D<br />
.197<br />
1/16“-27<br />
PM 10R..<br />
.197 PM 10L..<br />
.236<br />
1/8“-27<br />
PM 12R..<br />
.236 PM 12L..<br />
.315<br />
1/8“-27<br />
PM 16R..<br />
.315 PM 16L..<br />
Spare parts /<br />
D<br />
accessories (mm) inch<br />
1 piece 1 piece<br />
PM 10 ... (10) .394 10001230/M1,8X3,8/T06 7883305/TORX/T06<br />
PM 12 ... (12) .472 7883215/M2,2X4,0/T07 7724105/TORX/T07<br />
PM 16 ... (16) .630 7883214/M3,0X5,7/ T08 7724106/TORX/T08<br />
Page<br />
PM 10.. PM 12.. PM 16..<br />
14 14 14<br />
A<br />
Drawing shows right-hand tool
1.5D (=l 2 )<br />
2.25D (=l 2 )<br />
ProfileMaster Ø .787-1.260 inch<br />
Tools / radial application<br />
Type,<br />
description<br />
L D<br />
(mm) d1 d2 l1 l2 l3 f A<br />
PM 20R-1.5D-E<br />
PM 20R-2.25D-E<br />
PM 20L-1.5D-E<br />
PM 20L-2.25D-E<br />
R<br />
L<br />
(20)<br />
.787<br />
(20)<br />
.787<br />
1.000<br />
1.000<br />
-<br />
1.260<br />
-<br />
1.260<br />
5.906<br />
4.415<br />
5.906<br />
4.415<br />
1.181<br />
1.772<br />
1.181<br />
1.772<br />
-<br />
2.165<br />
-<br />
2.165<br />
.394<br />
.394<br />
1/4“-18<br />
PM 20R..<br />
PM 20L..<br />
PM 25R-1.5D-E<br />
PM 25R-2.25D-E<br />
PM 25L-1.5D-E<br />
PM 25L-2.25D-E<br />
R<br />
L<br />
(25)<br />
.984<br />
(25)<br />
.984<br />
1.250<br />
1.250<br />
-<br />
1.575<br />
-<br />
1.575<br />
7.087<br />
5.233<br />
7.087<br />
5.233<br />
1.476<br />
2.217<br />
1.476<br />
2.217<br />
-<br />
2.858<br />
-<br />
2.858<br />
.492<br />
.492<br />
1/4“-18<br />
PM 25R..<br />
PM 25L..<br />
PM 32R-1.5D-E<br />
PM 32R-2.25D-E<br />
PM 32L-1.5D-E<br />
PM 32L-2.25D-E<br />
R<br />
L<br />
(32)<br />
1.260<br />
(32)<br />
1.260<br />
1.500<br />
1.500<br />
-<br />
1.969<br />
-<br />
1.969<br />
7.874<br />
6.215<br />
7.874<br />
6.215<br />
1.890<br />
2.835<br />
1.890<br />
2.835<br />
-<br />
3.465<br />
-<br />
3.465<br />
.630<br />
.630<br />
1/4“-18<br />
PM 32R..<br />
PM 32L..<br />
Spare parts /<br />
D<br />
accessories (mm) inch<br />
1 piece 1 piece<br />
PM 20 ... (20) .787 7722111/M3,5X7,2/T15 7724103/TORX/T15<br />
PM 25 ... (25) .984 7783209/M3,5X8,6/T15 7724103/TORX/T15<br />
PM 32 ... (32) 1.260 10001785/M5,0X10,8/T20 7724104/TORX/T20<br />
inch<br />
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts<br />
Ordering example: 3 pieces PM 20L-1.5D<br />
Page<br />
PM 20.. PM 25.. PM 32..<br />
14 14 14<br />
A<br />
Drawing shows right-hand tool<br />
11
12<br />
1.5D (=l 2 )<br />
2.25D (=l 2 )<br />
ProfileMaster Ø .630-.787 inch<br />
Type,<br />
description<br />
L DNOM (mm) DAX d1 d2 l1 l2 l3 f A<br />
PM 16R-1.5D-E<br />
PM 16R-2.25D-E<br />
PM 16L-1.5D-E<br />
PM 16L-2.25D-E<br />
R<br />
L<br />
(16)<br />
.630<br />
(16)<br />
.630<br />
.630-∞<br />
.630-∞<br />
.750<br />
.750<br />
-<br />
.984<br />
-<br />
.984<br />
5.012<br />
3.890<br />
5.012<br />
3.890<br />
1.035<br />
1.508<br />
1.035<br />
1.508<br />
-<br />
1.921<br />
-<br />
1.921<br />
.224<br />
.224<br />
1/8“-27<br />
PM 16L..<br />
PM 16R..<br />
PM 20R-1.5D-E<br />
PM 20R-2.25D-E<br />
PM 20L-1.5D-E<br />
PM 20L-2.25D-E<br />
R<br />
L<br />
(20)<br />
.787<br />
(20)<br />
.787<br />
.787-∞<br />
.787-∞<br />
1.000<br />
1.000<br />
-<br />
1.260<br />
-<br />
1.260<br />
6.016<br />
4.590<br />
6.016<br />
4.590<br />
1.291<br />
1.882<br />
1.291<br />
1.882<br />
-<br />
2.276<br />
-<br />
2.276<br />
.283<br />
.283<br />
1/4“-18<br />
PM 20L..<br />
PM 20R..<br />
Spare parts /<br />
D<br />
accessories (mm) inch<br />
1 piece 1 piece<br />
PM 16 ... (16) .630 7883214/M3,0X5,7/T08 7724106/TORX/T08<br />
PM 20 ... (20) .787 7722111/M3,5X7,2/T15 7724103/TORX/T15<br />
PM 16.. PM 20..<br />
14 14<br />
Tools / axial application<br />
inch<br />
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts<br />
Ordering example: 3 pieces PM 16R-2.25D<br />
Page<br />
Details see<br />
page 32<br />
= D NOM<br />
D AXmin<br />
A<br />
Drawing shows right-hand tool
1.5D (=l 2 )<br />
2.25D (=l 2 )<br />
ProfileMaster Ø .984-1.260 inch<br />
Type,<br />
description<br />
L DNOM (mm) DAX d1 d2 l1 l2 l3 f A<br />
PM 25R-1.5D-E<br />
PM 25R-2.25D-E<br />
PM 25L-1.5D-E<br />
PM 25L-2.25D-E<br />
R<br />
L<br />
(25)<br />
.984<br />
(25)<br />
.984<br />
.984-∞<br />
.984-∞<br />
1.250<br />
1.250<br />
-<br />
1.575<br />
-<br />
1.575<br />
7.217<br />
5.363<br />
7.217<br />
5.363<br />
1.606<br />
2.346<br />
1.606<br />
2.346<br />
-<br />
2.988<br />
-<br />
2.988<br />
.362<br />
.362<br />
1/4“-18<br />
PM 25L..<br />
PM 25R..<br />
PM 32R-1.5D-E<br />
PM 32R-2.25D-E<br />
PM 32L-1.5D-E<br />
PM 32L-2.25D-E<br />
R<br />
L<br />
(32)<br />
1.260<br />
(32)<br />
1.260<br />
1.260-∞<br />
1.260-∞<br />
1.500<br />
1.500<br />
-<br />
1.969<br />
-<br />
1.969<br />
8.043<br />
6.384<br />
8.043<br />
6.384<br />
2.059<br />
3.004<br />
2.059<br />
3.004<br />
-<br />
3.634<br />
-<br />
3.634<br />
.461<br />
.461<br />
1/4“-18<br />
PM 32L..<br />
PM 32R..<br />
Spare parts /<br />
D<br />
accessories (mm) inch<br />
1 piece 1 piece<br />
PM 25 ... (25) .984 7883209/M3,5X8,6/T15 7724103/TORX/T15<br />
PM 32 ... (32) 1.260 10001785/M5,0X10,8/T20 7724104/TORX/T20<br />
PM 25.. PM 32..<br />
14 14<br />
Tools / axial application<br />
inch<br />
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts<br />
Ordering example: 3 pieces PM 25R-2.25D<br />
Page<br />
Details see<br />
page 32<br />
= D NOM<br />
D AXmin<br />
A<br />
Drawing shows right-hand tool<br />
13
14<br />
Size<br />
-M20<br />
PM -1.5D PM -2.25D<br />
10-13 10-13<br />
ProfileMaster<br />
Inserts<br />
Uncoated Coated<br />
groove<br />
Chip<br />
Type,<br />
description<br />
x<br />
(mm)<br />
y<br />
(mm)<br />
inch<br />
l s d1 r<br />
10 PM 10LG 201504-M20 M20 (2,0) .079 (1,5) .059 .197 .083 .083 .016<br />
10 PM 10RG 201504-M20 M20 (2,0) .079 (1,5) .059 .197 .083 .083 .016<br />
12 PM 12LG 201804-M20 M20 (2,0) .079 (1,8) .071 .236 .091 .098 .016<br />
12 PM 12RG 201804-M20 M20 (2,0) .079 (1,8) .071 .236 .091 .098 .016<br />
16 PM 16LG 252004-M20 M20 (2,5) .098 (2,0) .079 .315 .110 .134 .016<br />
16 PM 16RG 252004-M20 M20 (2,5) .098 (2,0) .079 .315 .110 .134 .016<br />
20 PM 20LG 302504-M20 M20 (3,0) .118 (2,5) .098 .394 .146 .157 .016<br />
20 PM 20RG 302504-M20 M20 (3,0) .118 (2,5) .098 .394 .146 .157 .016<br />
25 PM 25LG 353004-M20 M20 (3,5) .138 (3,0) .118 .492 .177 .173 .016<br />
25 PM 25RG 353004-M20 M20 (3,5) .138 (3,0) .118 .492 .177 .173 .016<br />
32 PM 32LG 404004-M20 M20 (4,0) .157 (4,0) .157 .630 .220 .236 .016<br />
32 PM 32RG 404004-M20 M20<br />
Steel<br />
Stainless<br />
Cast iron<br />
(4,0) .157 (4,0) .157 .630 .220 .236 0,4<br />
Non ferrous metals<br />
Heat resistant<br />
Hard materials<br />
= Main application<br />
= Extended application<br />
= International CERATIZIT range, for present availability see price list<br />
Ordering example: 20 pieces PM 10LG 201504-M20 CTC1435<br />
Page<br />
CTC1435<br />
CTP2440
Drilling<br />
feed (ipr)<br />
.0063<br />
.0055<br />
.0047<br />
.0039<br />
.0031<br />
.0024<br />
.0016<br />
.0008<br />
Face turning<br />
ap (inch)<br />
.236<br />
.197<br />
.157<br />
.118<br />
.079<br />
.039<br />
ProfileMaster<br />
Cutting depth / feed rate<br />
.0020 .0039 .0059 .0087 .0098 .0118 .0138 .0157<br />
feed (ipr)<br />
15
16<br />
Longitudinal turning<br />
ap (inch)<br />
.394<br />
.354<br />
.319<br />
.276<br />
.236<br />
.197<br />
.157<br />
.118<br />
.079<br />
.039<br />
ap (inch)<br />
.319<br />
.276<br />
.236<br />
.197<br />
.157<br />
.118<br />
.079<br />
.039<br />
ProfileMaster<br />
Cutting depth / feed rate<br />
.0020 .0039 .0059 .0087 .0098 .0118 .0138 .0157<br />
.0020 .0039 .0059 .0087 .0098 .0118 .0138 .0157<br />
feed (ipr)<br />
feed (ipr)
Radial grooving - internal + external<br />
feed (ipr)<br />
.0102<br />
.0094<br />
.0087<br />
.0079<br />
.0070<br />
.0063<br />
.0055<br />
.0047<br />
.0039<br />
.0031<br />
.0024<br />
.0016<br />
.0008<br />
ProfileMaster<br />
Feed rate<br />
17
18<br />
Longitudinal turning<br />
ap (inch)<br />
.236<br />
.197<br />
.157<br />
.118<br />
.079<br />
.039<br />
Face turning<br />
ap (inch)<br />
.236<br />
.197<br />
.157<br />
.118<br />
.079<br />
.039<br />
ProfileMaster<br />
Depth of cut / feed rate<br />
.0020 .0039 .0059 .0087 .0098 .0118 .0138 .0157<br />
.0020 .0039 .0059 .0087 .0098 .0118 .0138 .0157<br />
feed (ipr)<br />
feed (ipr)
Axial grooving - internal + external<br />
feed (ipr)<br />
.0102<br />
.0094<br />
.0087<br />
.0079<br />
.0070<br />
.0063<br />
.0055<br />
.0047<br />
.0039<br />
.0031<br />
.0024<br />
.0016<br />
.0008<br />
ProfileMaster<br />
Feed rate<br />
With PM 10 and PM 12 axial grooving is not possible.<br />
19
20<br />
A<br />
R<br />
F<br />
N<br />
S<br />
H<br />
Workpiece<br />
material Type of treatment / alloy VDI 3323<br />
Non alloyed steel<br />
Low alloyed steel<br />
High alloyed steel<br />
Corrosion resistant steel<br />
Stainless steel<br />
Grey cast iron<br />
Grey cast iron with<br />
spheroidal graphite<br />
Tempered iron<br />
Aluminium<br />
wrought alloys<br />
Aluminium<br />
cast alloys<br />
Copper and<br />
copper alloys (bronze,<br />
brass)<br />
Non metal<br />
materials<br />
Heat resistant<br />
alloys<br />
Titanium alloys<br />
annealed ≤ 0,15% C<br />
annealed 0,15% - 0,45% C<br />
tempered ≥ 0,45% C<br />
annealed<br />
tempered<br />
tempered<br />
annealed<br />
tempered<br />
annealed ferritic<br />
tempered martensitic<br />
annealed ferritic / martensitic<br />
quenched austenitic<br />
quenched duplex<br />
hardened martensitic / austenitic<br />
non hardened<br />
hardened<br />
perlitic / ferritic<br />
perlitic / martensitic<br />
ferritic<br />
perlitic<br />
ferritic<br />
perlitic<br />
non hardened < 12% Si<br />
hardened < 12% Si<br />
non hardened > 12% Si<br />
hardened and tempered<br />
Tempered steel<br />
hardened and tempered<br />
Chilled castings cast<br />
Tempered cast iron hardened and tempered<br />
* Rm = maximum strength, measured in MPa<br />
Cutting data<br />
Grades / material<br />
machining alloy stock (1% Pb)<br />
brass, red bronze<br />
bronze<br />
lead-free copper and electrolytic copper<br />
thermosetting plastics<br />
fi bre-reinforced plastics<br />
hard rubber<br />
annealed Fe-base<br />
hardened Fe-Fe-base<br />
annealed Ni- or Co-base<br />
hardened Ni- or Co-base 30 - 58 HRC<br />
cast Ni- oder Co-base 1500 - 2200 Nmm2 pure titanium<br />
alpha + beta alloys<br />
group<br />
Hardness<br />
CTC<br />
1435<br />
v c<br />
HB [sfm]<br />
1 125 459 - 918<br />
2 150 - 250 328 - 656<br />
3 300 262 - 590<br />
6 180 328 - 656<br />
7 / 8 250 - 300 262 - 525<br />
9 350 230 - 459<br />
10 200 328 - 590<br />
11 350 197 - 459<br />
12 200 328 - 656<br />
13 325 262 - 492<br />
14 200 328 - 656<br />
14 180 328 - 590<br />
14 230 - 260 –<br />
14 330 –<br />
15 180 394 - 820<br />
16 260 394 - 820<br />
17 160 361 - 820<br />
18 – 361 - 820<br />
19 130 328 - 820<br />
20 230 328 - 820<br />
21 60 –<br />
22 100 –<br />
23 80 –<br />
24 90 –<br />
25 130 –<br />
26 – –<br />
27 – –<br />
28 90 –<br />
29 100 –<br />
29 100 –<br />
29 – –<br />
30 – –<br />
31 200 –<br />
32 280 –<br />
33 250 –<br />
34 – –<br />
35 – –<br />
36 R 440* m –<br />
37 R 1050* m –<br />
38 55 HRC –<br />
39 60 HRC –<br />
40 400 –<br />
40 55 HRC –
CTP<br />
2440<br />
vc [sfm]<br />
394 - 820<br />
262 - 590<br />
197 - 492<br />
262 - 590<br />
197 - 492<br />
197 - 394<br />
262 - 525<br />
164 - 394<br />
164 - 656<br />
164 - 492<br />
164 - 656<br />
164 - 590<br />
164 - 328<br />
164 - 262<br />
–<br />
–<br />
–<br />
–<br />
–<br />
–<br />
328 - 1640<br />
328 - 984<br />
328 - 1640<br />
328 - 984<br />
328 - 656<br />
328 - 1640<br />
328 - 1640<br />
328 - 984<br />
328- 984<br />
262 - 590<br />
197 - 492<br />
328 - 820<br />
66 - 164<br />
66 - 131<br />
49 - 82<br />
33 - 66<br />
33 - 66<br />
164 - 394<br />
98 - 164<br />
–<br />
–<br />
–<br />
–<br />
Cutting data<br />
Grades / material<br />
21
22<br />
Material<br />
Blue: steel<br />
machining, cementation,<br />
tempered and constructional<br />
steels<br />
Green: non ferrous metals<br />
and non metals<br />
Al wrought and Al cast alloys,<br />
copper, copper alloys, non<br />
metal materials<br />
Machining application type<br />
MasterGuide<br />
Based on VDI 3323 CERATIZIT‘s MasterGuide divides<br />
materials into six main groups.<br />
Each is given a colour, according to the system partly<br />
adopted in ISO 513.<br />
Yellow: stainless steel<br />
ferritic Cr-steels, austenitic<br />
CrNi-steels, martensitic Crsteels,<br />
duplex steels<br />
Orange: heat resistant<br />
alloys / titanium<br />
Ni-/Co-base-alloys,<br />
Ti-alloys<br />
Red: cast iron<br />
grey cast iron, tempered iron,<br />
spheroidal cast iron, sintered<br />
iron<br />
White: hard materials<br />
hardened steels (≥45 HRC),<br />
chilled castings, hard cast<br />
irons<br />
Each coloured segment is divided into three sections, and<br />
each section indicates the relevant machining application<br />
type:<br />
R = Rough machining M = Medium machining F = Fine machining
Application<br />
MasterGuide<br />
The ideal application area for each insert is indicated by a<br />
black circle. Extended applications are indicated by an open<br />
circle. The CERATIZIT MasterGuide provides you with an easily<br />
understandable structure for choosing a product and enables<br />
you to reduce grade and geometry stocks.<br />
● Main application<br />
○ Extended application<br />
The right indexable insert at a glance<br />
Main application:<br />
Medium machining of steel and cast iron<br />
Extended application:<br />
Medium machining of stainless steels<br />
23
24<br />
CTC1435<br />
(P35, M30, K20)<br />
CTP2440<br />
(P40, M35, K25)<br />
Toughness:<br />
Wear resistance:<br />
Toughness:<br />
Wear resistance:<br />
Grade description<br />
Steel<br />
Composition:<br />
Co 9.5%; composite carbides 6.5%; WC rest<br />
Grain size: 1 - 2 μm<br />
Hardness: HV 1400<br />
Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B)<br />
+ Al 2 O 3 + Ti (C,N,B); 6 μm<br />
0<br />
0<br />
2 4 6<br />
2 4 6<br />
8 10<br />
Composition:<br />
Co 9.5%; composite carbides 6.5%; WC rest<br />
Grain size: 1 - 2 μm<br />
Hardness: HV 1400<br />
Coating specification: PVD, TiAIN, 3 - 5 μm<br />
8 10
CTC1435<br />
(P35, M30, K20)<br />
CTP2440<br />
(P40, M35, K25)<br />
Toughness:<br />
Wear resistance:<br />
Toughness:<br />
Wear resistance:<br />
Grade description<br />
Stainless steel<br />
Composition:<br />
Co 9.5%; composite carbides 6.5%; WC rest<br />
Grain size: 1 - 2 μm<br />
Hardness: HV 1400<br />
Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B)<br />
+ Al 2 O 3 + Ti (C,N,B); 6 μm<br />
0<br />
0<br />
2 4 6<br />
2 4 6<br />
8 10<br />
Composition:<br />
Co 9.5%; composite carbides 6.5%; WC rest<br />
Grain size: 1 - 2 μm<br />
Hardness: HV 1400<br />
Coating specification: PVD, TiAIN, 3 - 5 μm<br />
8 10<br />
25
26<br />
CTC1435<br />
(P35, M30, K20)<br />
CTP2440<br />
(P40, M35, K25)<br />
Toughness:<br />
Wear resistance:<br />
Toughness:<br />
Grade description<br />
Cast iron<br />
Composition:<br />
Co 9.5%; composite carbides 6.5%; WC rest<br />
Grain size: 1 - 2 μm<br />
Hardness: HV 1400<br />
Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B)<br />
+ Al 2 O 3 + Ti (C,N,B); 6 μm<br />
0<br />
0<br />
2 4 6<br />
Heat resistant alloys / titanium<br />
Wear resistance:<br />
2 4 6<br />
8 10<br />
Composition:<br />
Co 9.5%; composite carbides 6.5%; WC rest<br />
Grain size: 1 - 2 μm<br />
Hardness: HV 1400<br />
Coating specification: PVD, TiAIN, 3 - 5 μm<br />
8 10
Grade<br />
description<br />
CTC1435<br />
CTP2440<br />
Standard<br />
designation<br />
HC-P35<br />
HC-M30<br />
HC-K20<br />
HC-P40<br />
HC-M35<br />
HC-K25<br />
Grade overview<br />
Application range Material group<br />
05 15 25 35 45<br />
01 10 20 30 40 50<br />
01 10 20 30 40 50<br />
05 15 25 35 45<br />
A R F N S H<br />
Steel<br />
Stainless<br />
Cast iron<br />
Non ferrous<br />
metals<br />
Heat<br />
resistant<br />
materials<br />
Main application range<br />
Extended application<br />
Hard<br />
materials<br />
27
28<br />
Edge chipping<br />
Type of wear Workpiece<br />
problems<br />
Chip control<br />
Built-up edges<br />
Flank wear<br />
raise, increase<br />
large influence<br />
raise, increase<br />
small influence<br />
Plastic deformation<br />
ProfileMaster<br />
Problems / corrective measures<br />
Type of problem<br />
Vibrations<br />
Surface quality<br />
Chip too long (snarl chip)<br />
Chip too short (fragmented chip)<br />
avoid, reduce<br />
large influence<br />
Cutting speed<br />
Feed rate<br />
avoid, reduce<br />
small influence<br />
Corrective<br />
measures<br />
Cutting material<br />
Clamping of tool<br />
Clamping of workpiece<br />
Overhang<br />
Tip height<br />
Cooling lubricant<br />
Wear resistance<br />
Toughness<br />
control,<br />
optimize<br />
use<br />
Cutting values<br />
Selection of inserts<br />
General criteria
Mounting of the insert<br />
Axial displacement of the machine<br />
Displacement in x-direction<br />
Through hole<br />
ProfileMaster<br />
Application recommendations<br />
Angular error Turret position error<br />
With through holes a sharp-edged disk is<br />
created as tool break-out occurs.<br />
Safety measures are necessary.<br />
29
30<br />
Off-centre drilling<br />
ProfileMaster<br />
Application recommendations<br />
Due to the special construction of Profi leMaster tools and inserts off-centre drilling is possible. Thus desired devations<br />
from the tool‘s nominal diameter can be obtained (see table below).<br />
Tool type<br />
D (mm) inch D (inch) min D (inch)<br />
max<br />
PM 10R/L ... (10) .394 .388 .472<br />
PM 12R/L ... (12) .472 .467 .591<br />
PM 16R/L ... (16) .630 .624 .748<br />
PM 20R/L ... (20) .787 .780 .945<br />
PM 25R/L ... (25) .984 .976 1.142<br />
PM 32R/L ... (32) 1.260 1.252 1.496<br />
Machining across centre line<br />
Situation:<br />
In case of insuffi cient movement of the machine across the<br />
centre line the external diameter can not be machined with<br />
the same tool.<br />
Nominal tool ∅ Drilling ∅<br />
Maximum movement<br />
across centre line<br />
Solution:<br />
Use a right-hand<br />
Profi leMaster tool
Coolant supply<br />
2<br />
1<br />
v c = 492 sfm a p = .0394 inch<br />
ProfileMaster<br />
Coolant supply / “Masterfinish” effect<br />
ProfileMaster is equipped with a unique coolant and<br />
chip removal system.<br />
3<br />
In order to guarantee efficient chip evacuation from a hole,<br />
a minimum coolant pressure of<br />
3 – 6 bar (optimum 7 – 10 bar) is required.<br />
“Masterfinish” effect<br />
Surface test on material Ck60 (1.1221)<br />
with a standard boring bar and ProfileMaster<br />
.0039 .0059 .0087 .0098 .0118 .0138 .0157 .0177<br />
1<br />
2<br />
3<br />
Cooling of the insert cutting edge<br />
General coolant stream<br />
“Chipbooster“ prevents chips<br />
from getting stuck between tool<br />
and workpiece<br />
feed (ipr)<br />
31
32<br />
Axial grooving - axial application<br />
D Nom<br />
(mm) inch<br />
D AXmin<br />
inch<br />
D AXmin = D Nom<br />
D AXmax = ∞<br />
D AXmax<br />
inch<br />
(16) .630 .630 ∞<br />
(20) .787 .787 ∞<br />
(25) .984 .984 ∞<br />
(32) 1.260 1.260 ∞<br />
Situation<br />
D AX >= D Nom<br />
ProfileMaster<br />
Application recommendations<br />
= D NOM<br />
D AXmin<br />
Situation<br />
D AX < D Nom<br />
If the first cut is carried out with a diameter<br />
which is smaller than the nominal tool<br />
diameter D Nom (90° application), collision<br />
will result.
Technical data:<br />
Workpiece: HSK100 adapter<br />
Material: 1.2343 / X38 CrMoV 5 1<br />
Strength: approx. 1100 N/mm 2<br />
Tool: PM 16R-1.5D<br />
Insert: PM 16RG 252004-M20 CTP2440<br />
Competitor: 2 tools<br />
Technical data:<br />
Workpiece: Piston<br />
Material: 1.0756 / 35SPb20+C<br />
Tool: PM 16R-1.5D<br />
Insert: PM 16RG 252004-M20 CTC1435<br />
Competitor: 2 tools<br />
ProfileMaster<br />
Machining examples 1 + 2<br />
Criteria:<br />
> Problems due to lack of turret positions<br />
> Optimisation of machining time<br />
Cutting data:<br />
v c [sfm] 492<br />
a p [inch] .0394<br />
f [inch/rev.] .0059<br />
Result:<br />
> Only 1 tool instead of 2<br />
> 1 free turret position<br />
Criteria:<br />
> Increase in productivity<br />
> Insuffi cient quality of groove surface<br />
Cutting data: CERATIZIT WB<br />
v c [sfm] 344<br />
a p [inch] .0118 – .197<br />
f [inch/rev.] Turning .0059 .0039<br />
Grooving .0024<br />
Result:<br />
> Machining time reduced by 50%<br />
> Enhanced groove quality<br />
33
Headquarters: CERATIZIT S.A.<br />
Main site Luxembourg<br />
CERATIZIT Luxembourg Sarl<br />
Route de Holzem, B.P. 51<br />
L-8201 Mamer<br />
Tel.: +352 312 085-1<br />
Fax: +352 311 911<br />
E-Mail: info@ceratizit.com<br />
www.ceratizit.com<br />
Sales Companies<br />
Austria<br />
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Tel: +359 (66) 803 811<br />
Fax: +359 (66) 801 608<br />
E-Mail: info.bulgaria@ceratizit.com<br />
China<br />
CERATIZIT China Ltd.<br />
Room 1201-1204<br />
Hollywood Centre<br />
233 Hollywood Rd., Sheung Wan<br />
Hong Kong<br />
Tel.: +852 (2542)-1838<br />
Fax: +852 (2854) 3777<br />
E-Mail: info.china@ceratizit.com.hk<br />
France<br />
CERATIZIT France Sarl<br />
Pontoise<br />
20, Rue Lavoisier<br />
F-95300 Pontoise<br />
Tel.: +33 (1) 3433-3180<br />
Fax: +33 (1) 3030-9339<br />
E-Mail: info.france@ceratizit.com<br />
Germany<br />
CERATIZIT Deutschland GmbH<br />
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Tel.: +49 (2173) 97 25-0<br />
Fax: +49 (2173) 97 25-25<br />
E-Mail: info.deutschland@ceratizit.com<br />
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Tel.: +49 (7123) 9201-0<br />
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E-Mail: info.dettingen@ceratizit.com<br />
Main site Austria<br />
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A-6600 Reutte/Tyrol<br />
Tel.: +43 (5672) 200-0<br />
Fax: +43 (5672) 200-502<br />
E-Mail: info.austria@ceratizit.com<br />
Great Britain<br />
CERATIZIT UK Ltd.<br />
Cliff Lane<br />
Grappenhall<br />
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Tel.: +44 (1925) 261-161<br />
Fax: +44 (1925) 267-933<br />
E-Mail: info.uk@ceratizit.com<br />
India<br />
CERATIZIT India Pvt. Ltd.<br />
58, Motilal Gupta Road<br />
Barisha<br />
IN-700 008 Kolkata<br />
Tel.: +91 (33) 2494-5435<br />
Fax: +91 (33) 2494-1472<br />
Telex: 021 8142 ihm in<br />
E-Mail: info.india@ceratizit.com<br />
Italy<br />
CERATIZIT Italia SpA<br />
Piazza F. Martelli, 7<br />
I-20162 Milano<br />
Tel.: +39 (02) 6441-111<br />
Fax: +39 (02) 6611-6040<br />
E-Mail: info.italia@ceratizit.com<br />
Japan<br />
CERATIZIT Japan Ltd.<br />
3-13-9, Mizuho<br />
Shizuoka 421 - 0115<br />
Tel.: +81 (54) 268 1060<br />
Fax: +81 (54) 257 8181<br />
E-Mail: info.japan@ceratizit.com<br />
Luxembourg<br />
CERATIZIT Luxembourg Sarl<br />
Route de Holzem, B.P. 51<br />
L-8201 Mamer<br />
Tel.: +352 312 085-1<br />
Fax: +352 311 911<br />
E-Mail: info@ceratizit.com<br />
Netherlands<br />
CERATIZIT Nederland B.V.<br />
Bergrand 224<br />
NL-4707 AT Roosendaal<br />
Tel.: +31 (165) 55 08 00<br />
Fax: +31 (165) 55 61 76<br />
E-Mail: info.nederland@ceratizit.com<br />
Spain<br />
CERATIZIT Ibérica SL<br />
Offi ce Pozuelo<br />
Vía de las Dos Castillas, 9c<br />
Portal 2, Bajo B<br />
E-28224 Pozuelo (Madrid)<br />
Tel.: +34 (91) 351-0609<br />
Fax: +34 (91) 351-2813<br />
E-Mail: info.iberica@ceratizit.com<br />
CERATIZIT Ibérica SL<br />
Offi ce Bilbao<br />
Avda. Mazarredo 41 1 Izqda.<br />
E-48009 Bilbao<br />
Tel.: +34 (944) 23 71 18<br />
Fax: +34 (944) 23 97 18<br />
E-Mail: info.bilbao@ceratizit.com<br />
USA<br />
CERATIZIT USA Inc.<br />
777 Old Clemson Road<br />
Columbia<br />
South Carolina 29229<br />
Toll free: +1 (800) 334 1165<br />
Tel.: +1 (803) 736 1900<br />
Fax: +1 (803) 736 1902<br />
E-Mail: info.usa@ceratizit.com
293/ 0<br />
7000626<br />
293 USA 06.05<br />
We reserve the right to make technical changes<br />
for improvement of the product.
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