Revolutionize turning with dynamometer from Kistler

Ceratizit intends to revolutionize industrial turning technology with its High Dynamic Turning (HDT) system and FreeTurn tooling. Thanks to this innovative system, users can manufacture complex geometries with just one tool. During an extensive series of tests, measurement technology from Kistler was deployed to record the forces acting on the cutting edge. Ceratizit's engineers gained critical insights from the reliable values supplied by the dynamometer.

For over 95 years, Ceratizit has pioneered the development of sophisticated hard material solutions for cutting and wear protection. The company develops and produces highly specialized cutting tools, indexable inserts, carbide rods and wear parts. With more than 9,000 employees and 34 production facilities across the globe  - backed by a sales network of over 70 branches  - the Ceratizit Group is a global player in the carbide sector. Innovative solutions from Ceratizit are deployed in the mechanical engineering and toolmaking sectors as well as the automotive, aerospace and medical industries  - the list could go on.

New machining method revolutionizes turning

Ceratizit's experts have now developed a new machining method that is set to revolutionize turning. High Dynamic Turning (HDT) and the FreeTurn tools included in the system allow the cutting head to move freely  - so the approach angle of the cutting edge can be chosen freely at any point during the machining operation. FreeTurn tools feature a new type of indexable insert that can consist of several different cutting edges. This breakthrough allows both pull- and push-type machining of workpieces. Chip breaking can also be optimized, and the chip can be moved out of the cut zone.

HDT offers a key advantage: only one tool is needed to carry out all the familiar turning operations such as roughing, finishing, contour turning, face turning and longitudinal turning. This means that every contour of a turned part can be produced with no need to change the tool. The result: from now on, parts can be fully machined with just one single FreeTurn tool instead of the large numbers of different tools that were required in the past. Tool changes as well as empty tool runs are vastly reduced  - leading to increased productivity. And as yet another benefit, tool costs are slashed.

The values obtained with measurement technology from Kistler are plausible. Industry trusts them. And that means we can supply machine and spindle manufacturers with reliable values that they too can trust.

Dr. Uwe Schleinkofer, Head of R&D Cutting Tools

 

 

Less force is applied thanks to this innovative concept

A further advantage of HDT is the new angle of approach, which directs the cutting force vertically through the tool into the spindle. This reduces the load on the machine, making it possible to work with higher process parameters. The free choice of approach angle also extends the life expectancy of the cutting edge.

The first tests have been completed successfully, so the system is currently undergoing the release procedure for series use. For this purpose, Ceratizit's developers need detailed and reliable values for the forces that occur in the system. This data is essential to improve their understanding of the tool properties in the cutting process. Manufacturers of machines and controls as well as CAM software providers have a particular need for this information so they can drive their developments ahead towards their defined goals.

Extensive series of tests with support from Kistler

Ceratizit has already been putting its trust in solutions from Kistler for over 30 years. And in this project too, products from the Swiss measurement technology specialist have played a key part. The 9171A 4-component rotating cutting force dynamometer (RCD) was used to measure the cutting forces. This measuring instrument features a modular structure and is compatible with all commonly used machine spindles. It measures the forces acting on the cutting edge in all three axes, and can also calculate the torque on the basis of these values. Piezoelectric sensor technology gives the RCD a very high sampling rate coupled with sensitivity across an extremely wide force range. These assets guarantee that the measurement data is meaningful as well as accurate. Transmission of measured values and energy is contact-free, so wear is eliminated.

The measuring chain was completed with the 5238B signal conditioner, which is responsible for the energy supply, signal transmission and system control in the test setup at Ceratizit. Measurement range settings and adjustments to the low-pass filter are made manually on the signal conditioner or via the serial interface. System activation and data acquisition are handled via the DynoWare software from Kistler. The measurement signals are also available as analog voltage signals (±10 volts).

Cutting force measuring instrument from Kistler supplies reliable values

The tests were carried out during summer 2019 at the Innovation Center of Ceratizit Austria GmbH in Reutte (Austria). The first objective was to approach the maximum performance capability of the HDT system. Different values for the feed rate and cut depth were selected for this purpose. The steepness of the approach angle for the FreeTurn tool was then gradually increased. The dynamometer from Kistler supplied detailed and reliable values for the forces occurring during this process. This data was compared to the results for a conventional turning tool of type PCLNL 2525 M12.

Onsite support for the project was provided by Lukas Janotta, the Kistler application engineer responsible for cutting processes. He advised the Ceratizit engineers as they performed the series of tests. The DynoWare software from Kistler was used for detailed visualization, recording and analysis of the forces occurring during the tests. This made it possible to validate the results from previous simulations with real measurement values. As the end result, the customer gained in-depth insights into cutting force conditions that were previously hidden.

2020. 10. 5.
How does a digital measuring chain for piezoelectric sensors work as part of a complex vehicle test stand?
2020. 9. 18.
Convincing test results: The Ohio Department of Transportation goes on to apply Lineas from Kistler for traffic monitoring.
2020. 8. 20.
Precision is the key to top performance: how measurement technology from Kistler supports the development team at EMUGE-FRANKEN
2020. 7. 22.
Quality assurance solutions by Kistler like ComoNeo ensure highest accuracy at TSP Precision Tooling in Shanghai.
2020. 6. 9.
Kistler supports Ceratizit in the development of HDT. This enables complex geometries to be produced with just one tool.
2019. 11. 15.
Process monitoring systems and cavity pressure sensors from Kistler help to reduce the amount of scrap drastically
2019. 10. 23.
How measurement technology from Kistler contributes toward boosting high-end powertools' quality
2019. 8. 15.
How the ANALYSE system from Kistler is enhancing safety and transparency in the field of fastening technology
2019. 7. 17.
Turkey opts for weight enforcement with WIM technology from Kistler
2019. 6. 24.
For the next manned flight to the moon: safety that can be measured
2019. 6. 20.
Segregation of good and bad parts every 1.5 seconds: process monitoring with Kistler enables high quality for over 5 million parts per year.
2019. 5. 14.
In order to achieve excellent quality for its components and medical devices, Tessy Plastics chose sensors and solutions from Kistler.
2019. 4. 18.
A renowned manufacturer of electrical appliances trusts testing and sorting systems by Vester to improve its quality.
2019. 4. 2.
NFL's Jaguars boost their fitness levels with Kistler.
2019. 3. 25.
By using process monitoring from Kistler, not only the assembly of electric fuses is validated, but even the function of the sensors itself.
2019. 3. 18.
How to determine the fitness level of an athlete efficiently? A practical report on the Quattro Jump force plate system from Kistler.
2018. 12. 17.
Thanks to precise Weigh in Motion technology from Kistler, Hungary's roads are sustainably protected against overloaded vehicles.
2018. 11. 27.
Bang&Clean relies on Kistler's precise measurement of ignition processes and pressure wave propagation
2018. 10. 10.
Sartorius applies the process monitoring system ComoNeo from Kistler and thereby increases the process quality during injection molding
2018. 10. 8.
The Dortmund Technical University tests the new MicroDyn 9109AA cutting force dynamometer from Kistler and breaks new ground for developing its micromachining processes.
2018. 8. 31.
The ZF company operates a software-controlled Kistler fastener test bench with an integrated vibration unit.
2018. 8. 14.
BIG Daishowa, headquartered in Osaka, Japan, is one of the leading producers of tool holders for the machining industry. Each year the company produces over half a million collet chucks. Their products are developed using, among other resources, Kistler’s cutting force measuring device.
2018. 7. 16.
Enhanced quality and efficiency in mobile crane manufacture – thanks to the test stand for torque tools by Kistler
2018. 4. 11.
The world’s largest provider of rail transport technology relies on Kistler’s measurement expertise. Thanks to the only crash wall of its kind in the world, the impact forces of the trains and their components can be precisely measured and analyzed.
2017. 11. 14.
In the development of cooling lubricants, Blaser Swisslube relies on Kistler's measurement expertise.
2017. 8. 11.
Applus IDIADA relies on DTI in-dummy technology from Kistler for Test Device for Human Occupant Restraint (THOR).
2017. 1. 4.
Road safety is a central topic in vehicle development. Through accurate measurements, Kistler helps increase the chance of survival in crashes.
2016. 12. 22.
Kistler makes progress in vehicle development possible
2016. 12. 22.
Kistler Sensor Correvit® SFII measures world record
2016. 12. 20.
Kistler sensors deliver a maximum in data quality under any conditions.
2016. 11. 7.
Kistler pressure sensors enabled the Rosetta space probe to fly for 6.4 billion kilometers.
2016. 10. 5.
Since the end of 2015 FC Basel is using Kistler force plates to reduce the dropout of young talents.
2016. 8. 17.
Kistler makes the difference in the crucial sports moments with its Performance Analysis System for Swimming.
2016. 2. 19.
Determination of Pump Efficiency with Kistler KiTorq Measuring Flange System
2015. 11. 4.
Piezoelectric Measurements with CompactRIO™
2015. 6. 15.
Measurement Solutions for Automotive Test Systems
2015. 5. 8.
Quality Assurance in the Automotive Industry
2015. 3. 2.
How Brose improves the quality of its two-component production and automatically separates defective parts
2014. 12. 2.
The Kistler Group pursues a growth policy that is both ambitious and sustainable – and strategic acquisitions are one of its core elements. ‘Strategic’ means that Kistler deliberately selects companies which can achieve more together with Kistler than they ever could by continuing alone. The takeover of Dr. Staiger Mohilo & Co. GmbH in 2006 enabled Kistler to grow jointly with the acquired company...
2014. 12. 2.
After a ten-year voyage, the Rosetta space probe's Philae landing module finally touched down on the surface of comet ‘Chury’.
2011. 8. 23.
HEWI and its Customers Benefit from Cavity Pressure Technology
2011. 2. 15.
End-to-end process monitoring for critical medical moldings
2011. 2. 7.
Cavity pressure measurement eliminates short shots at Fischer GmbH & Co KG of Sinsheim/Germany
연락처
(max 25 Mb)