Chain wheel drum

Description

Our customer, a subcontractor to the engineering industry, was looking for a solution to apply back spot faces for the bolting that does the job without the time-consuming reclamping of the workpiece. The time used for the reclamping amounted to 2 x 0.5 hours per workpiece (alignment and zeroing not included yet)

Application details

Application details

  • Bore diameter: Ø21.0 mm
  • Countersink diameter: Ø40.0 mm with corner radius R1.2
  • Number of bores per workpiece: 40
  • Material: G-22 Ni MoCr5-6
  • Machine: Lathe Mazak Integrex 70YB / Horizontal machining

Proposed solution

Proposed solution

HEULE proposed their counterboring tool SOLO2. SOLO2 possesses a particular feature. When the spindle is in idle state, the blades are extended. Only at a speed of over approx. 2000 rev/min, the blades are retracting. This way, the tool head can travel across the bore to access the back side of the bore. In contrary to the SOLO1 tool where the blades are extended by gravity, SOLO2 allows low spindle speeds to machine tough materials or interrupted bore edges.

Tool choice: SOLO2 21.0 / 40.0 mm, working length 50 mm

Blade choice: SOLO carbide blade A type coating

Machining parameters:

  • Working speed: 300 rev/min.
  • Feed: 0.03 mm/rev.

Customer benefits

Customer benefits

Of primary importance are the cost savings generated by the complete machining without having to reclamp the workpiece. At a yearly volume of 200 workpieces, a reduction of over 200 hours is resulting. Also after deduction of the tool investment, there is still a most attractive net cost saving.

Customer satisfaction

Customer satisfaction

The statements given by the machine operator were the following:

  • Despite the interrupted bore edge the tool is running very smoothly.
  • The blade showed hardly any wear after 20 back spot faces despite the very tough material (1000 - 1200 N/mm2).
  • The cutting surface is very smooth (< Ra3.2).
  • The tool is running reliably.

The prodcution manager is highly pleased about the process capable solution with SOLO. The labour-intensive reclamping and readjustment of the large workpiece belongs to the past and he is able to take a ready-to-use part off his machine. This fact increases the efficiency considerably.