hp tooling 2020 #1

materials & tools
The plastic step boring bar consists of
a tubular lightweight base body that
is made using conventional cutting
pro cesses. The diameters of the stator
bore are fashioned using additively
manufactured steps containing cartridges
equipped with PCD or indexable
inserts.
Carbon-fibre reinforced
special plastic
These steps are the absolute highlight
of the tool, as they are created additively
using a special plastic developed
by CERATIZIT. The high degree
of rigidity of the plastic is due to the
integrated additional materials. Having
been optimised topologically during
the development, they are, despite
their minimal weight, able to divert
the machining forces generated
into the base body. The special plastic
is also vibration-damped, while the
3D printing method allows the coolant
holes to be configured as required.
The coolant can therefore be channelled
in the best way to flush the
chips to the rear and out of the hole.
The cartridges for each step are
equipped with PCD cutting edges or
indexable inserts. Not a standard tool
holder, but a design that prevents
the tightening torque of the indexable
insert from acting on the plastic.
The cartridge also has an electronic
component that enables fine adjustments
to be carried out digitally on
the indexable insert. A display can
be docked via a digital interface and
cutter adjustments then performed to
micrometre-level precision.
Modular design
The modular design featuring base
body and steps allows the light-weight
counterboring tool to be configured as
a multi-step tool entirely to a customer’s
requirements to facili tate the complete
machining of the stator bore in a
single operation. Additional enhancements
to hold an additional tool on
the front, e.g. for the rotor shaft bearing,
are under consideration.
Available quickly
Customers will love the fact that
the delivery period is so short, even
though everything’s made to measure.
CERATIZIT holds the base body
as a semi-finished product in stock -
The new design and forming fixture of the high-end boring tool
is printed entirely from steel
with a flexible KOMET ABS or HSK
interface. The plastic steps are produced
very quickly on a 3D printer.
Without having to wait too long, the
customer therefore receives a tool that
can be used to machine stator holes
with previously unattainable levels of
efficiency.
The advantages at a glance:
➤ flexible machining of stator bore
to customer’s specification;
for rough machining, finish
machining or a combination
of both
➤ facility for additional tools
possible
➤ extremely precise machining
results (tolerance class IT6)
➤ modular tool design
➤ topology-optimised, additively
manufactured plastic steps
➤ digitally adjustable tool cartridges
can be fitted
➤ optimised coolant channelling
for flushing chips out of the bore
➤ short delivery times
Tools with intelligence
CERATIZIT has always made the availa
bility of digital support for its users a
priority. KOMET KOMlife, the newly
developed digital maintenance indicator,
is a helpful add-on that further
increases process security. KOMET
KOMlife can be fitted to the two new
fine boring tools as well as any rotating
tool with a diameter of 50 mm
and above.
With its KOMlife predictive maintenance
system, CERATIZIT has set another
milestone in the development of
innovative maintenance strategies.
KOMlife allows operational data to
be recorded directly on the tool itself
and displayed on an integrated display,
which is activated using a magnetic
stylus. The maintenance indicator
can be adapted to a customer’s specific
needs - such as when to change
a cutting edge - using the adjustable
maintenance interval. If the interval
is exceeded, a flashing red LED indicates
that maintenance is overdue. To
acquire operational data digitally, the
recorded data can be retrieved by the
KOMlife app using the dynamic and
patented QR code.
The advantages at a glance:
➤ low-cost, digital maintenance
indicator
➤ autonomous data acquisition
on the tool itself
➤ integrated display
➤ dynamic QR code - can be read
using KOMlife app
➤ for all rotating tools with
diameters of 50 mm and above
12 no. 1, 2020, March