Reduce Machining Time and Tool Costs

Innovative turning technology at Senratian is used to revolutionize tool production processes.

Only by relying on advanced, future-oriented tool solutions can future competition be invincible. It is for this reason that the head of Senratian's Besigheim, Germany, production site decided to use the new High Dynamics Turning (HDT, High Dynamic Turning) technology and FreeTurn tools to manufacture their high-quality tools, with very good results.

HDT turning technology has won several innovation awards since its debut in AMB 2018 and has received wide attention in the global machining field. The FreeTurn tool is mounted on the milling spindle of the car milling complex during Senratian, allowing for free adjustment at the main angle of 360 degrees, ensuring that the work piece is always machined at the optimum cut-in angle. This makes it more possible to optimize production: flexible machining of almost any work tool profile, perfect chip control, and even higher yields, longer tool life and higher process stability.

What changes can HDT and FreeTurn bring to our customers?

Installing tool machining work tools on the milling spindle may sound a bit more unexpected than traditional turning processes, but it is now a reality. New highly dynamic turning technology and FreeTurn tools are being used by a growing number of manufacturers. Dr. Thomas Ledermann, non-standard tool production manager at the Besigheim tool production site at Senratian, has been constantly following the innovations in turning processes. "At our Besigheim production site, we produce a wide range of high-quality cutting tools using highly optimized processes. The changes that high dynamic turning technology and FreeTurn tools can bring have successfully attracted our attention. We decided to use this new turning technology in production to see if it could really bring about what it calls revolutionary changes. Thomas Ledermann explains.

Besigheim machining experts are encouraged by the significant reduction in the number of tools using the FreeTurn tool, as the introduction to the tool mentions that a FreeTurn blade can be used in a variety of turning situations. For Mr. Ledermann, this advantage alone is enough to allow them to choose FreeTurn because it means a significant cutter cost savings.

Significant advantage: Save tool costs.

Paul Höckberg, turning product manager at Senratian, who was involved in the optimization of the production process, agrees with Thomas Ledermann: "The most significant advantage of HDT and FreeTurn is the savings in tool costs. In the past, roughing, finishing, contour turning, end-face turning, and vertical turning in the traditional way required several tools, and now we only need one FreeTurn tool to do it all. "However, after Besigheim used the FreeTurn cutter, we quickly realized that this was clearly not its only advantage. Dynamic turning technology is also significantly superior to conventional machining methods in terms of cutting speed and energy efficiency. "

The DMG MORI CTX beta 1250 TC is the machine of choice for this optimization and can meet all the requirements of high dynamic turning. "This processing center is very popular in the market and HDT technology is mature. This also means that many manufacturers are in a condition to use our FreeTurn tools. Höckberg stressed. The tool consists of a trans-positionable blade and shank and is optimized with the Siemens Sinumerik 840D control system and Open Mind 5-axis simulation and after-processing software - with stunning results.

The cutting speed is beyond imagination.

"As expected, we have reduced the number of tools. The previous 3 tools were successfully replaced with 1 FreeTurn tool for complete machining of the work piece. Ledermann says. But saving 2 cutters was not surprising, and what really shocked the production manager was the cutting parameters used. "The cutting speed we use to machine work pieces is Vc 220 m / min, the yield f 0.48 mm / r, and the depth of the cut ap 4 mm. At finishing, the cutting speed can even reach 400 m / min. There is no doubt that FreeTurn is superior to traditional turning. Thomas Ledermann concludes.

Significant reductions in production time, costs and energy consumption.

The product manager, Höckberg, was also surprised by the result: "We know that our FreeTurn is excellent. However, we never thought that mold steel (X40CrMoV51) could achieve such a strong cutting speed when machined. "Another set of comparisons with traditional turning processes is also very clear and intuitive validation of the effective changes that HDT and FreeTurn have brought." When processing a single work piece, we were able to save 2.25 minutes of production time, production costs of EUR 3.53, and energy consumption of 0.42 kW/h. "

Ensure competitive advantage.

HDT technology and FreeTurn tools will gradually be used in Besigheim's day-to-day production due to excellent optimization results. Programming with Siemens NX CAD/CAM software is also ideal for HDT. "We look forward to gradually transforming our traditional turning methods into HDT turning technology and FreeTurn." "With this process optimization, we can gain a significant competitive advantage," says Thomas Ledermann. "

FreeTurn works.

High dynamic turning technology allows freeTurn tools to be precisely positioned and used for machining work parts by milling spindles, unlike traditional static adjustments using a tool handle or tool rod. Since the milling spindle rotates around its center at a full degree of freedom of 360 degrees, it can be adjusted for high flexibility for the work tool - it can be machined from a variety of angles and directions. Benefits: One blade enables multiple applications without the need for a knife change. The blades are composited with different cutting edges to meet a wide range of machining needs. This means that all turning processes, such as roughing, finishing, profile turning, end face turning, and portrait turning, can be achieved with 1 tool. As a result, more and more manufacturers want to apply these benefits to their production.