High Dynamic Turning – the revolution has begun
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
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