Wheel set machining - Sanimex

Wheel set machining

CERATIZIT - the parent companies
Headquarters and parent company in MAMER / Luxembourg
Parent company in REUTTE / Austria
Direct sales and distribution partners
2

CERATIZIT Services
SUPPORT
Our CERATIZIT product and application specialists look forward to supporting you with regard to the
optimisation of your milling strategies. Their long-standing experience together with international
know-how represent a solid foundation for a result-oriented cooperation with our customers.
WinTool:
An electronic catalogue which supports you when specifying cutting tools.
It is possible to produce data sheets relating to complete tool assemblies.
WinTool CD in 4 languages no.: 136
Techstore:
The on-line availability check and possibility to order 24 hours a day is only one
of the numerous features. You will be provided with a maximum of up-to-the-minute
information and services with only a few mouse clicks.
www.ceratizit.com
ADDITIONAL LITERATURE
Catalogue “Tools and inserts for milling“
no.: 126
“Tizilogue“ CD no.: 209
TRAINING
At the Ceratizit cutting tool lab standards for safe tool
application are developed.
State-of-the-art machines and facilities create the necessary
conditions for extensive performance tests and are utilised to
train our customers and application specialists.
3

Main grades
GM507
(P10, M10, K15)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 5.8%; composite carbides 6.5%; WC rest;
Grain size: 1 - 2 µm
Hardness: HV 1550
Coating specification:
CVD
Ti (C,N) + Ti (C,N) + Ti (N,B) + Al 2
O 3
+ D.S.
18 µm
Properties/application:
> Excellent heat resistance
For high-performance turning
GM517
(P15, M15, K15)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 5.8%; composite carbides 6.4%;
WC rest
Grain size: 1 - 2 µm
Hardness: HV 1480
Coating specification:
CVD
Ti (C,N) + Ti (C,N) + Ti (N,B) + Al 2
O 3
+ D.S.
18 µm
SR127
(P25, M20, K20)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 6.0%; composite carbides 0.6%;
WC rest
Grain size: 1 - 2 µm
Hardness: HV 1450
Coating specification:
CVD
TiC + Ti (C,N) + TiN + Al 2
O 3;
12 µm
GM527
(P25, M20)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 6.0%; composite carbides 0.6%;
WC rest
Grain size: 1 - 2 µm
Hardness: HV 1450
Layer system:
CVD
Ti (C,N) + Ti (C,N) + TiN + Ti (N,B) +
Ti (C,N) + TiN; 12 µm
Properties/application:
> Low tendency to stick
4

Main grades
GM537
(P35, M25)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 8.0%; composite carbides 4.2%; WC rest
Grain size: 1 - 2 µm
Hardness: HV 1330
Coating specification:
CVD
Ti (C,N) + Ti (C,N) + TiN + Ti (N,B) +
Ti (C,N) + TiN; 12 µm
Properties/application:
> Low tendency to stick
GM40
(P35, M30)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 11.0%; composite carbides 12.0%; WC rest
Grain size: 1 - 2 µm
Hardness: HV 1420
Coating specification:
CVD
TiC + Ti (C,N) + TiN; 5,5 µm
Properties/application:
> Universally applicable grade
S40T
(P40, M40)
Composition:
Co 11.0%; composite carbides 12.0%;
WC rest
Grain size: 1 - 2 µm
Hardness: HV 1420
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
CTC1125
(P25, M20)
Toughness:
0 2 4 6 8 10
Wear resistance:
0 2 4 6 8 10
Composition:
Co 7,0%; composite carbides 8,0%; WC rest
Grain size: 1 - 2 µm
Hardness: HV 1450
Coating specification:
CVD
Ti (C,N) + Ti (C,N) + Ti (N,B) + Al 2
O 3
+ D.S.
18 µm
Properties/application:
> grade with peripheral zone
5

Chip grooves
Application range:
SNMG 211040SN-DB
a p : 2,0 - 13,0 mm
f: 0,5 - 2,0 mm
> multi purpose groove
> excellent chip control in
a wide fi eld of application
Application range:
SNMG 211040SN-DF
a p : 1,0 - 6,0 mm
f: 0,5 - 1,7 mm
> soft cutting geometrie
> good chip control at
small depth of cut
Application range:
SNMG 190616EN-TMR
a p : 1,5 - 9,0 mm
f: 0,3 - 1,4 mm
> chip groove for double
sided insert
> for new wheels and
wheel rings
Application range:
SNMM 190616EN-TR
SNMM 250724EN-TR
a p : 2,0 - 13,0 mm
f: 0,4 - 1,6 mm
> excellent for roughing
> for new, solid wheels
6

Chip grooves
Application range:
SNMM 190616SN-TRR
SNMM 250724SN-TRR
a p : 1,0 - 13,0 mm
f: 0,3 - 1,2 mm
> for new, solid wheels
Application range:
RCMT 2507MOSN-SM
RCMT 3209MOSN-SM
a p : 1,0 - 13,0 mm
f: 0,2 - 1,6 mm
> special for turning
new wheel
> for new, solid wheels
Application range:
LNUX 191940SN-25
a p : 3,0 - 14,0 mm
f: 0,6 - 1,8 mm
> insert to roughing and
old machines
7

Inserts
SNMG / SNMM
[mm]
ordering description / grade
l d s d 1 r
SNMG 211040SN-DF GM517 21,0 21,0 10,5 7,84 4,0
SNMG 211040SN-DB GM507 21,0 21,0 10,5 7,84 4,0
SNMG 211040SN-DB GM517 21,0 21,0 10,5 7,84 4,0
SNMG 211040SN-DB SR127 21,0 21,0 10,5 7,84 4,0
Ordering example: 20 pieces SNMG 211040SN-DB GM507
r
d
d 1
l
s
[mm]
ordering description / grade
l d s d 1 r
SNMG 190616EN-TMR GM527 19,0 19,0 6,35 7,94 1,6
SNMM 190616EN-TR GM527 19,0 19,0 6,35 7,94 1,6
SNMM 190616EN-TR GM537 19,0 19,0 6,35 7,94 1,6
SNMM 190616SN-TRR GM527 19,0 19,0 6,35 7,94 1,6
SNMM 190616SN-TRR GM537 19,0 19,0 6,35 7,94 1,6
SNMM 250724EN-TR GM517 25,4 25,4 7,94 9,12 2,4
SNMM 250724EN-TR GM527 25,4 25,4 7,94 9,12 2,4
SNMM 250724EN-TR GM537 25,4 25,4 7,94 9,12 2,4
SNMM 250724SN-TRR GM517 25,4 25,4 7,94 9,12 2,4
SNMM 250724SN-TRR GM527 25,4 25,4 7,94 9,12 2,4
SNMM 250724SN-TRR GM537 25,4 25,4 7,94 9,12 2,4
Ordering example: 20 pieces SNMM 190616SN-TRR GM527
8

Inserts
CNMX / RCMT
r
[mm]
l d s d 1 r
CNMX 190740SN GM507 19,05 19,05 7,94 7,93 4,0
CNMX 190740SN GM517 19,05 19,05 7,94 7,93 4,0
7°
d1
d
d 1
l
s
ordering description / grade
Ordering example: 20 pieces CNMX 190740SN GM507
d
s
[mm]
ordering description / grade
d s d 1
RCMT 3209MOSN-SM GM517 32,0 9,52 9,50
RCMT 3209MOSN-SM CTC1125 32,0 9,52 9,50
RCMT 2507MOSN-SM GM527 25,0 7,94 7,20
RCMT 2507MOSN-SM GM537 25,0 7,94 7,20
RCMT 2006MOSN-SM GM40 20,0 6,35 6,50
RCMT 2006MOSN-SM GM537 20,0 6,35 6,50
RCMT 2006MOSN-SM SR127 20,0 6,35 6,50
RCMT 1606MOSN-SM GM517 16,0 6,35 5,30
RCMT 1606MOSN-SM GM537 16,0 6,35 5,30
RCMT 1606MOSN-SM SR127 16,0 6,35 5,30
RCMT 1606MOSN-SM S40T 16,0 6,35 5,30
Ordering example: 20 pieces RCMT 2006MOSN-SM GM537
9

Inserts
LNUX
r
d
d 1
s
l
[mm]
ordering description / grade
l d s d 1 r
LNUX 191940SN-DB GM507 19,05 19,05 10,0 6,35 4,0
LNUX 191940SN-DB GM517 19,05 19,05 10,0 6,35 4,0
LNUX 191940SN-DB SR127 19,05 19,05 10,0 6,35 4,0
LNUX 191940SN-25 SR127 19,05 19,05 10,0 6,35 4,0
LNUX 301940SN-DB GM507 19,05 30,00 12,0 6,35 4,0
LNUX 301940SN-DB GM517 19,05 30,00 12,0 6,35 4,0
Ordering example: 20 pieces LNUX 191940SN-DB GM507
10

Cartridge / Spare parts
RK 3223... RK 3219-19...
[mm]
drawing shows right hand version
cartridge
type,
ordering description
l 1 l 2 h 1 f 1 b
insert
availability
RK 3223-19R/L
LNUX 19... x
42,5 35 32 23,0 22,5
RK 3223-30R/L LNUX 30... x
RK 3219-19R/L 42,5 35 32 19,1 18,6 LNUX 19... x
x = ex stock or short delivery
supply details: cartridge body, lever, screws and key, but without indexable insert
ordering example: 1 piece RK 3223-30R
spare part
RK 3223-19R/L
RK 3223-30R/L
RK 3219-19R/L
lever screw
S 000425/S/SK 3MM 7882202/SW 3 H 028443/H
key
lever
ordering example: 1 piece H 028443/H
11

Basic holder for wheel set machines / spare parts
DPK-60N-S21
DPH 555N / 106He
[mm]
type,
ordering description
tool head
DPK-60N-S21
tool shank
DPH 5555N / 106He
l l 1 h h 1 f b
insert
availability
70 40 55 45 60 – SNMG 21... x
122 – 55 – – 55 r
r= semi-standard, limited stocks
x= ex stock or short delivery
supply details:
ordering example:
basic holder, power screw, threaded pin, pin, lever, support pad,
shim clip, mounting pin, clamping screw and key
1 piece DPK-60N-S21
advice:
DPH 5555-N/106He is defi ned for Hegenscheidt 106. For all other machines, the machine type
and tool mounting have to be specifi ed. Price and delivery time upon request.
spare parts
power screw
lever screw lever support pad shim clip mounting pin key
7480412 (SW4)
DPK-60N-S21 7879001 S 033422 H 033442/H 3673051 R 033462/R M 022472/MO
7896919 (SW8)
ordering example: 1 piece S 033422
12

Basic holder for wheel set machines / spare parts
[mm]
drawing shows right hand version
type,
ordering description
l 1 b h h 1 f cartridge availability
RKH 5555-R/L 182 55 55 45 60 RK 32... r
r= semi-standard, limited stocks
supply details: basic holder, screws and key, but without indexable insert and cartridge
ordering example: 1 piece RKH 5555-R
advice:
Any dimensional changes must be covered by a manufacturing drawing for quotation
spare part
threaded pin
RKH 5555-R/L M6x16 7882202 (SW3)
key
ordering example:
1 piece 7882202 (SW3)
13

Basic holder for wheel set machines / spare parts
[mm]
drawing shows right hand version: RHK 5850-R
type,
ordering description
onfloor
RKH 6060-R/L
underfloor
RKH 5850-R/L
l 1 b h h 1 f cartridge availability
175 60 60 55 64 RK 32... r
200 58 50 55 55 RK 32... r
r= semi-standard, limited stocks
supply details: basic holder, screws and key, and cartridge
ordering example: 1 piece RKH 6060-R
advice:
Any dimensional changes must be covered by a manufacturing drawing for quotation
spare part
RKH 6060-R/L
RKH 5850-R/L
M6x16
threaded pin
7882202 (SW3)
key
ordering example:
1 piece 7882202 (SW3)
14

Basic holder for wheel set machines / spare parts
drawing shows right hand version
[mm]
type,
ordering description l 1 b h h 1 f
cartridge availability
E-10093R
E-10094R ; E-10095L r
150 50 50 50 57,6
E-10096L E-10097L ; E-10098R r
r= semi-standard, limited stocks ordering example: 1 piece E-10093R
spare part
E-10093R
E-10096L
M6x16
threaded pin
7882202 (SW3)
key
ordering example:
1 piece 7882202 (SW3)
cartridge
type,
ordering description
E-10098R
E-10095L
[mm]
l 1 l 2 b h 1 f 1
46,8 40 18,4 32 19,05
insert
CNMX
190740SN
availability
r
r
E-10094R
E-10097L
42,5 35 32 19,1 18,6
CNMX
190740SN
r
r
r= semi-standard, limited stocks ordering example: 1 piece E-10094R
spare part
E-10098R
E-10097L
E-10095L
E-10094R
ordering example: 1 piece R 033462/R
lever screw key
lever support pad shim clip mounting pin
S 033422 7480412 (SW4) H 033442/H E 10516/E R 033462/R M 022472/M
15

Types of wear
Flank wear
Reasons:
> Cutting speed too high
> Carbide grade with too low wear resistance
> Feed rate not adapted
Abrasion on fl ank,
normal wear after a certain
machining time.
Remedies:
> Reduce cutting speed
> Select more wear resistant carbide grade
> Adapt feed rate to cutting speed and cutting depth
(increase feed rate)
Edge chipping
Reasons:
> Grade with too high wear resistance
> Vibrations
> Feed rate too high or excessive cutting depth
> Interrupted cut
> Swarf damage
Through excessive mechanical
stress at the cutting edge fracture
and chipping can take place.
Remedies:
> Use tougher grade
> Use negative cutting edge geometry with chip groove
> Increase stability (tool, workpiece)
Cratering
Reasons:
> Too high cutting speed and / or feed rate
> Rake angle too shallow
> Grade with low wear resistance
> Insuffi cient coolant supply
The hot chip which is being
evacuated causes cratering
at the rake face of the cutting
edge.
Remedies:
> Reduce cutting speed and / or feed rate
> Increase coolant quantity and / or pressure,
optimise coolant supply
> Use grade which is more resistant to cratering
16

Types of wear
Plastic deformation
Reasons:
> Too high machining temperature,
resulting in softening of substrate
> Damaged coatings
Remedies:
> Reduce cutting speed
> Choose carbide grade with higher wear resistance
> Provide cooling
High machining temperature and
simultaneous mechanical stress
can lead to plastic deformation.
Built-up edges
Reasons:
> Too low cutting speed
> Too small rake angle
> Wrong cutting material
> Lack of cooling / lubrication
Built-up material / edges occur
when the chip is not evacuated
properly due to a too low cutting
temperature.
Remedies:
> Increase cutting speed
> Enlarge rake angle
> Apply TiN-coating
> Use emulsion with higher concentration
Insert breakage
Reasons:
> Excessive stress of cutting material
> Lack of stability
> Corner angle too small
> Excessive notching
Excessive stress of the insert
causes breakage.
Remedies:
> Use tougher cutting material
> Use protective edge chamfer
> Increase honing of edge
> Use more stable geometry
17

Your pointer to profit!
The CERATIZIT tooling concept helps to signifi cantly
increase productivity ? Conventional tooling systems.
Milling cutters especially designed for points sets?
machining combine well-established tangential inserts
with a new approach to the problem plus the well-known
performance of CERATIZIT hardmetal grades.
Furthermore, special tooling solutions are available for
planing rails.
Use the advantages of CERATIZIT points sets milling cutters:
especially stable construction makes for high machining safety and predictable tool life
even when machining manganese steels.
high-performance grades guarantee longer tool life and higher cutting speeds which subsequently
lead to cost reduction.
standardised tangential inserts permit varied applications.
and optimise your machining of points sets
Please ask your CERATIZIT
representative or your closest
dealer for more information.
18

Headquarters: CERATIZIT S.A.
Main site Luxembourg
CERATIZIT Luxembourg Sarl
Route de Holzem
L-8232 Mamer
Tel.: +352 312 085-1
Fax: +352 311 911
E-Mail: info@ceratizit.com
Main site Austria
CERATIZIT Austria Gesellschaft m.b.H.
A-6600 Reutte/Tyrol
Tel.: +43 (5672) 200-0
Fax: +43 (5672) 200-502
E-Mail: info.austria@ceratizit.com
www.ceratizit.com
Sales Companies
Austria
CERATIZIT Austria Gesellschaft m.b.H.
A-6600 Reutte/Tyrol
Tel.: +43 (5672) 200-0
Fax: +43 (5672) 200-502
E-Mail: info.austria@ceratizit.com
Bulgaria
CERATIZIT Bulgaria AG
Boulevard Stoletov 157
BG-5301 Gabrovo
Tel: +359 (66) 438-11
Fax: +359 (66) 801 608
E-Mail: info.bulgaria@ceratizit.com
China
CERATIZIT China Ltd.
Room 1201-1204
Hollywood Centre
233 Hollywood Rd., Sheung Wan
Hong Kong
Tel.: (+852) 2542-1838
Fax: (+852) 2854-3777
E-Mail: info.china@ceratizit.com.hk
France
CERATIZIT France Sarl
Office Pontoise
20, Rue Lavoisier
F-95300 Pontoise
Tel.: +33 (1) 3433-3180
Fax: +33 (1) 3030-9339
E-Mail: info.france@ceratizit.com
Germany
CERATIZIT Deutschland GmbH
Office Langenfeld
Hans-Böckler-Straße 10
D-40764 Langenfeld
Tel.: +49 (2173) 97 25-0
Fax: +49 (2173) 97 25-25
E-Mail: info.deutschland@ceratizit.com
CERATIZIT Deutschland GmbH
Office Bad Urach
Schützenstraße 29
D-72574 Bad Urach
Tel.: +49 (7125) 1501-0
Fax: +49 (7125) 8594
E-Mail: info.badurach@ceratizit.com
Great Britain
CERATIZIT UK Ltd.
Cliff Lane
Grappenhall
Warrington WA4 3JX
Tel.: +44 (1925) 261-161
Fax: +44 (1925) 267-933
E-Mail: info.uk@ceratizit.com
India
CERATIZIT India Pvt. Ltd.
58, Motilal Gupta Road
Barisha
IN-700 008 Kolkata
Tel.: +91 (33) 2494-5435
Fax: +91 (33) 2494-1472
Telex: 021 8142 ihm in
E-Mail: info.india@ceratizit.com
Italy
CERATIZIT Italia SpA
Piazza F. Martelli, 7
I-20162 Milano
Tel.: +39 (02) 6441-111
Fax: +39 (02) 6611-6040
E-Mail: info.italia@ceratizit.com
Japan
CERATIZIT Japan Ltd.
3-13-9, Mizuho
Shizuoka 421 – 0115
Tel.: +81 (54) 268 1060
Fax: +81 (54) 257 8181
E-Mail: info.japan@ceratizit.com
Luxembourg
CERATIZIT Luxembourg Sarl
Route de Holzem
L-8232 Mamer
Tel.: +352 312 085-1
Fax: +352 311 911
E-Mail: info@ceratizit.com
Netherlands
CERATIZIT Nederland B.V.
Bergrand 224
NL-4707 At Roosendaal
Tel.: +31 (165) 55 08 00
Fax: +31 (165) 55 61 76
E-Mail: info.nederland@ceratizit.com
Spain
CERATIZIT Ibérica SL
Offi ce Pozuelo
Vía de las Dos Castillas, 9c
Portal 2, Bajo B
E-28224 Pozuelo (Madrid)
Tel.: +34 (91) 351-0609
Fax: +34 (91) 351-2813
E-Mail: info.iberica@ceratizit.com
CERATIZIT Ibérica SL
Offi ce Bilbao
Avda. Mazarredo 41 1 Izqda.
E-48009 Bilbao
Tel.: +34 (944) 23 71 18
Fax: +34 (944) 23 97 18
E-Mail: info.bilbao@ceratizit.com
USA
CERATIZIT USA Inc.
777 Old Clemson Road
Columbia
South Carolina 29229
Toll free: +1 (800) 334 1165
Tel.: +1 (803) 736 1900
Fax: +1 (803) 736 1902
E-Mail: info.usa@ceratizit.com

152/ 1
152 EN 10.03
We reserve the right to make technical changes for
improvement of the product.