High Dynamic Turning – the revolution has begun

At EMO 2019, CERATIZIT launched the first standard range of products for the innovative High Dynamic Turning process. The tool manufacturer has therefore taken the next step in revolutionising turning. CERATIZIT was joined by big name machine tool and control system manufacturers as well as providers of CAD/CAM systems.

Since High Dynamic Turning (HDT) was presented at AMB, it has been a hot topic of discussion in the relevant trade magazines. There are few other topics that have been discussed and reported on more in the last few months than HDT and dynamic FreeTurn tools from CERATIZIT. This is hardly surprising as this new turning technology offers great potential for users. The milling spindle in turning-milling centres is used to achieve a 360° rotation clearance angle, which allows the tool to be positioned at any angle in relation to a workpiece. This not only allows flexible machining of almost any workpiece contour, it also allows optimum chip breakage, higher feeds and an increase in the tool service life, all the while maintaining maximum stability. As the cutting edges of the indexable inserts can have different properties, for example different point angles, corner radii or chip breakers, users can save time when it comes to changing tools, reduce the number of tool magazine positions and even use fewer tools.

Pioneers of the FreeTurn generation

Spanish company ROTOR has taken a keen interest in CERATIZIT’s turning technology, which has won a number of awards, including the AMB Award and the Best of Industry Award. The Madrid-based company is well-known around the world for its high-quality and precision manufactured bicycle components such as chain rings, cassettes, cranks and wheel hubs. The latter will now be manufactured using HDT and FreeTurn tools from CERATIZIT. CERATIZIT’s Innovation Center in Reutte has already convincingly proven that the new turning process optimises the production process and reduces the overall machining time. This was demonstrated by manufacturing a wheel hub on an EMCO Hypermill using High Dynamic Turning.

Saving tools and machining time

An indexable insert with two different cutting edges was used to manufacture the aluminium wheel hub. One cutting edge is used for roughing (1500 rpm, ap = 2 mm, f = 0.4 mm/rev) and one for finishing (2000 rpm, ap < 1 mm, f = 0.25 mm/rev). When using HDT, the approach angle can be changed during machining, making it possible to machine all contours in just one setup, even undercuts that would not be possible with a standard approach angle of 90°. The tool is also able to cut in both directions, saving time-consuming rapid moves and increasing efficiency. In comparison to the turning process normally used by ROTOR for wheel hubs, this machining process used four fewer tools and reduced the machining time by 30%. Looking at these figures, it is easy to see why the Spanish company is now working together with CERATIZIT to implement HDT.

The first HDT solutions at EMO

Since CERATIZIT presented High Dynamic Turning and FreeTurn tools at AMB 2018, a number of big name machine and control system manufacturers have begun developing solutions for an automated process. CAD/CAM providers have also begun to develop solutions for programming HDT-specific program sequences. A number of promising CAM programs were on show at EMO 2019 this year, including Open Mind and Siemens NX. CERATIZIT’s HDT and FreeTurn tools also generated a lot of excitement amongst the expert audience during the live presentations from machine manufacturers DMG Mori and Mazak.

FreeTurn is ready for launch

Right from the start of the High Dynamic Turning process, CERATIZIT has relied on an open source model, supplying all interested parties with the relevant information to allow them to help develop the HDT turning process. Meanwhile, the tool manufacturer devoted its attention to its core business, developing a standard range of FreeTurn tools. Four different indexable insert geometries were initially launched at EMO. This included indexable inserts for machining steel/stainless steel (2x roughing and 1x finishing, 3x roughing, symmetrical) and for aluminium (3 cutting edges, symmetrical). This initial range covers a number of applications. The holders are available with a range of different overhang lengths for each size and are available for the HSK-T and PSC machine interfaces.