Guhring at EMO 2013 Intelligence in Production with precision tools from Guhring In the spirit of the motto of this year s EMO, from 16th to 21th September in Hanover, Guhring is introducing trendsetting tools and product innovations within the meaning of intelligent production. Innovative tooling concepts enable the machining of hightech materials of the future. Our continuous tool optimisation guarantees increased productivity and economical manufacture. In hall 4, stand A42, you can experience Intelligence in Production. The following trade show highlights can be seen at EMO: PowerTap universal taps unbeatably cost-effective RF 100 A high-performance milling cutters for aluminium RT 100 T ALU vario spiral-fluted deep hole drills GühroSync the best of both systems HT 800 WP interchangeable insert drilling system for accurate holes HPC milling head revolution in PCD-technology MQL test station making performance visible CFRP milling cutter clean cutting edges without delamination HR 500 CAST reamer high-performance reaming in GGG 1
PowerTap range Suitable for all materials Whether cast iron, aluminium and aluminium alloys, stainless and acid-resistant, high-strength or general steels Guhring s PowerTap range provides powerful taps for the most popular threads. The golden ring on the PowerTap indicates with this universal tap that your choice is always spot on. State-of-the-art manufacturing technology guarantees highest quality at unbeatable cost-efficient prices. Universal spectrum The special geometry of Guhring s PowerTaps enables a broad application range and outstanding machining results. Long and constant tool life is achieved thanks to the optimal cutting edge geometry. PowerTap performance reliability with straight-fluted taps for through holes as well as with spiral tools for blind holes is achieved through optimised geometries. 2
RF 100 A high-performance milling cutters The specialist for aluminium and Al-wrought alloys RF 100 A is a new generation of high-performance milling cutters for machining aluminium. Nano-polished cutting edges Thanks to the innovative Guhring Nano-polishing procedure RF 100 A possesses an extremely smooth surface finish. Thus, up to 25% higher feed rates are possible whilst simultaneously providing a dramatic improvement in tool life. Optimal chip evacuation with vibration-free operation The newly developed cross centre face cutting geometry permits drilling, plunging or ramping operations with a near constant feed rate. The innovative flute geometry combined with an unequal helix angle of 39 /40 /41 enables optimal chip evacuation with vibration-free operation. 3
RT 100 T ALU vario Solid carbide spiral-fluted deep hole drills up to 30xD When developing the RT 100 T ALU vario drills Guhring attached great importance to cutting edge geometry and flutes. The spiral flutes with 30 /15 flute angle ensure optimal cutting edge form in the frontal area (30 ) with fast chip evacuation in the area thereafter (15 ). Optimal cutting edge geometry for chip evacuation The cutting edge geometry of the spiral-fluted deep hole drill RT 100 T ALU vario is optimised to produce chips that can be evacuated from deep holes as easy as possible. Furthermore, a high quality surface finish of the flutes gives the chips low frictional - resistance and evacuates the optimally formed chips quickly and problem-free from deep holes. 4
Application example cylinder head In the automotive industry, engine manufacture in particular is a typical application range for aluminium materials. With MQL machining a cylinder head the spiralfluted deep hole drill RT 100 T ALU vario could prove its efficiency: - drilling the main oil gallery - Ø 6.98 mm, drilling depth 2 x 190 mm - drilling both ends - material AlSi9 - MQL 2-channel 60 ml - vc = 150 m/min - vf = 1600 mm/min - Tool life: 3000 m PRESSE-INFORMATION Also ideally suited for 99.9 % copper The new flute and cutting edge geometry achieves optimal results also in near pure copper: - Ø 7mm, drilling depth 30XD - vc = 120 m/min - f = 0,07 mm/rev. - short chips - secure chip evacuation 5
GühroSync synchro chunk More accurate, robust and safer: the best of both systems Practical applications show that the spindle dynamics and the axis drive of machines create synchronisation errors during the tapping process. Such synchronisation errors result in high forces acting on the tool. This in turn reduces tool life and leads to defective threads. The solution for these problems was a combination of two excellent clamping technologies. GühroSync offers the advantages of synchro and hydraulic chucks in one system. Thanks to the unique application of long-lasting metal spring and polymer damping elements the axial and radial forces are perfectly sprung as well as dampened. Loading at the thread flank is reduced so tool life and process reliability are considerably increased. 6
The usual collet chuck holder gives way to a considerably more comfortable hydraulic chuck operation. Thus, the time and effort spent on clamping is reduced. Just one unique key is used for clamping, additional keys for locking or rings for sealing are not required. The positive drive of the tool by the hydraulic chuck optimally transmits the full torque. PRESSE-INFORMATION The smooth, corner-free design prevents contamination and swarf trapping during the machining process. The modular structure of the chuck enables various standard and special designs, i.e. longer or reduced diameter models. 7
HT 800 WP The complete interchangeable insert drilling system for highly-accurate holes in the diameter range from 11.00 to 40.00 mm HT 800 is the ideal drilling system for manufacturing large, highly-accurate holes in various materials. It is, for example, applied for wind turbines and hydropower stations, engine systems as well as gas and steam turbines. With the HT 800 WP interchangeable insert drilling system Guhring provides wear-resistant holders with high rigidity and powerful interchangeable inserts for holes in the diameter range from 11.00 to 40.00 mm. PRESSE-INFORMATION 8
Powerful drilling, pilot drilling and countersinking HT 800 WP interchangeable standard inserts are perfectly adapted to your specific area of application with regard to tool material, geometry and surface finish whether in steel, stainless steel, cast iron or aluminium. The HT 800 WP drilling system is designed for the drilling depths 1.5xD, 3xD, 5xD, 7xD and 10xD. Furthermore, there are holders and interchangeable inserts especially for pilot drilling and countersinking. High wear-resistance and tool life Even with deep drilling depths HT 800 WP holders ensure optimal chip evacuation from the hole thanks to its flute cross-section. Coolant ducts with maximum cross-section exiting in the flute guarantee a perfect cooling lubrication. Thanks to special, micro-machined cutting edges the interchangeable inserts of the HT 800 WP drilling system are especially wear-resistant. Rigid holders thanks to small increments Clamping screws with positive locking ensure a secure precise location of the interchangeable insert in the holder even on machines subject to heavy vibrations. The holders in 0.5 mm increments are available ex-stock. The flexible holder sizes reduce the wear on the holder body. In addition, the rigidity of the HT 800 WP is also increased thanks to the improved tool guidance in the hole. This in turn not only provides longer tool life but also results in improved workpiece surface quality. 9
HPC-milling from Hollfelder-Guhring A quantum leap in PCD milling technology With the new HPC milling cutter for the machining of aluminium Hollfelder-Guhring has achieved the next evolutionary step in PCD milling technology. Its extraordinary technical features such as chip guiding elements, radial coolant exits and 10x re-grindable PCD cutting edges enable maximum productivity and energy efficiency with low investment cost. 10
Ingenious chip evacuation When applying conventional face milling cutters the chips are uncontrolled and enter into the workpiece through the axially open chip chambers. However the replaceable chip guiding elements of the HPC milling cutter combined with the radial coolant exit divert the chips away from the workpiece. This prevents chips reaching the highly-sensitive internal areas of the workpieces. PRESSE-INFORMATION PCD cutting edges Thanks to the high number of teeth, i.e. 27 PCD cutting edges with Ø 125 mm, feed rates up to 60,000 mm/min are possible. The machining time is hence drastically reduced. The axial runout of the cutting edge is µm accurately adjustable. Subsequently it is possible to achieve a very high surface quality. Furthermore, the PCD cutting edges can be re-ground up to 10 times. Application examples The new HPC milling cutter is ideal for face milling cylinder heads, sealing or flange faces on, for example, transmission housings, oil sumps, crank casings etc.. The milling cutter provides good surface qualities as well as a defined peak-to-valley height. 11
Test station for the optimisation of minimal quantity lubrication (MQL) Making performance visible MQL-designed tools possess special coolant ducts for the finely dosed lubricants to be applied accurately and to reach the correct locations. Guhring has developed a specific MQL test station for the perfect functioning of their MQL tools. Hereby, the following is checked: PRESSE-INFORMATION - response time for the initial aerosol exit - time for constant aerosol flow - Verify that MQL process runs with constant oil volume 12
Variable and realistic inspection conditions The MQL inspection station offers the possibility of checking tools for 1-channel MQL systems as well as 2- channel MQL systems. There is the possibility of numerous options with regard to speed, MQL volume and air pressure. With the assistance of the inspection station records it is possible to check whether the lubricating medium exits evenly from the coolant ducts in order to ensure a sufficient lubrication of the cutting edges. If necessary, the coolant ducts can be modified accordingly. The MQL inspection station works at an operating speed of up to 16,000min -1. Thanks to an integrated motor spindle with automatic tool clamping realistic inspection conditions can be achieved. PRESSE-INFORMATION Optimising tool lubrication With the assistance of the data, the functionality of the tool lubrication can be perfected for the customer. The application of Guhring s inspection station increases process reliability and optimises MQL manufacturing efficiency. 13
CFRP milling cutter for the machining of composite materials Delamination-free milling of unidirectional CFRP The machining of modern materials such as carbon fibre reinforced plastics (CFRP) is a growing challenge for tooling manufacturers. In order to economically machine the latest generation of this high-tech material, effective high-tech tools are required that above all prevent the delamination or fibre projections on the component as well as any thermal damage whilst operating with extreme efficiency. The problem With the new CFRP varieties there is a noticeable trend towards reduced resin content and above all the unidirectional orientation of the fibres. Whilst the fibres in woven condition are firmly embedded in the resin fibre matrix, in the unidirectional CFRP they lie next to each other in the resin. The result shows a lack of interlocking embedding. This development considerably affects the reliability of the machining process for these materials as, for example, milling can cause the fibres to easily tear out of the composite. The higher the cutting forces, the greater the effect. Typical delamination of a milled unidirectional CFRP workpiece edge and unidirectional CFRP workpiece edge when milled with Guhring s new CFRP milling cutter. 14
Intelligent solutions from Guhring Guhring s research centre for composite materials developed a new milling cutter with an innovative cutting edge arrangement. Two cutting edges are positioned to each other at a helix angle of 25, in addition it possesses unequal spacing of the cutting edges at the circumference a practice perfected with carbide milling cutters and reamers. The advantages of this new geometry are: no tendency to premature delamination extremely smooth operation, even with unstable clamping delamination-free machining longer tool life PRESSE-INFORMATION Milling cutter with PCD cutting edges and new Guhring cutting edge geometry and milling cutter with diamond coating and new Guhring cutting edge geometry. 15
HR 500 CAST power reamer Special tool for the machining of GGG Guhring s HR 500 CAST high-performance reamer is now available as a version especially for machining grey cast iron (GGG). Now it is also possible in GGG to achieve surface finish qualities below Ra 1.2. Its design in solid carbide provides the reamer with high rigidity and stiffness against torsional and radial forces. Therefore, as usual with HR 500 it also achieves a long tool life. Thanks to the combination of grey cast iron geometry with the extremely hard Guhring Signum-coating built-up edges and premature circular land abrasion are effectively prevented. The new HR 500 CAST for GGG machining achieves cutting speeds from 120 to 250 m/min, high feed rates of approximately 0.15 mm per cutting edge and surface finish qualities of below Ra 1.2 naturally with maximum process reliability and hole quality. 16
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