Tiger tec Silver - ISO P Generation The Rocket

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1 i-pac12-1 Tiger tec Silver - ISO P Generation The Rocket 1

2 Table of content 1. General Information TigerTec Silver Results Main features / Difference 2. Geometry MP5 / RP5 Product description Lab tests Field tests 3. Sales information General Handbook 2 January 2012 VM Kussmaul

3 Field test results competitors Ceratizit; 1 ZCCT; 2 Valenite; 3 Sumitomo; 3 Mitsubishi; 4 Safety; 1 Coromant; 26 Coromant Walter Kennametal Seco Kyocera; 4 Kyocera Mitsubishi Sumitomo Seco; 5 Valenite ZCCT Ceratizit Safety Kennametal; 8 Walter; 24 Total: 81 Tests January 2012 VM Kussmaul

4 Field test results competitors 3; 4% 4; 5% Wins / Gewonnen Equal / Gleich Lost / Verloren 74; 91% Total: 81 Tests January 2012 VM Kussmaul

5 Field test results against Coromant Workpiece / Reference Reference Geometry Grade Difference Material: component: Geometry grade Walter Walter Walter [%] Result Remarks: Mat.100Cr6 camshaft -MF GC4215 -FP5 WPP10S 200% pos C45 Bar -WF GC4215 -FP5 WPP10S 187% pos 4150 MOD., BHN WORM GEAR, -WM FP5 WPP20S 157% pos 20MnCr5 Reduction gear -PF GC4205 -FP5 WPP10S 150% pos much better chip control 16MnCr5 Reverse shaft -MF FP5 WPP10S 150% pos St24 Fly wheel -PF GC4225 -FP5 WPP20S 150% pos 4150 MOD. WORM GEAR, -WM FP5 WPP20S 133% pos 18CrMo4 & 17NiCrMo7 Shaft -LC GC4215 -FP5 WPP20S 125% pos Cor vc was 230m/min & f 0,2mm / Walter vc was 250m/min and f 0, Profile roller -QM GC4225 -FP5 WPP10S 100% equal 20NiCr6 (1.5752) Satelite helic 34 -PR MP3 WPP20S 200% pos 41Cr4 Joint housing -PF GC4215 -MP3 WPP10S 200% pos C45 Wheel shaft -PM GC4225 -MP3 WPP10S 140% pos much better chip control 26MnB5 Profile sleeve -PM GC4225 -MP3 WPP20S 133% pos 26MnB6 Profile sleeve -PM GC4225 -MP3 WPP20S 133% pos (35NC6) Planet Carrier -PR MP3 WPP20S 131% pos C56 Forging Wheel Hub -PF MP3 WPP10S 131% pos good chip control C45 forging Sideshaft -PM MP3 WPP20S 129% pos good chip control C45 forging Sideshaft -QM MP3 WPP10S 129% pos good chip control 42CD4 Shock absorber -PM GC4225 -MP3 WPP10S 125% pos C45 Bar -PR GC4205 -MP3 WPP10S 110% pos X19CrNiMo4 Roll spindle -WMX GC4225 -MP3 WPP10S 100% equal 42CrMo4 Remarks: Input shaft -PM GC4225 -MP5 WPP20S 113% pos Better chip control with -MP5 vs. -PM C45 Flange -PM GC4225 -RP5 WPP20S 133% pos 18CrMo4 Shaft -PM GC4215 -RP5 WPP20S 125% pos 18CrMo4 GC42XX are Shaft currently the -PFoldest GC4215 grades from -RP5 the WPP10S big carbide 125% companies pos Cor Vc and 240m/min have / Walter a weak Vc270m/min C45 performance. Flange -PM GC4225 -RP5 WPP20S 120% pos Cor insert radius 1,6mm / Walter 1,2mm PR / SVPR: 5 January 2012 VM Kussmaul

6 Field test results against Walter old Workpiece / Reference Reference Geometry Grade Difference Material: component: Geometry grade Walter Walter Walter [%] Result Remarks: 41CrS4 vergütet Rm(1000N/mm2) Ventigehäuse -NF3 WPP10 -FP5 WPP10S 333% pos Shorter chips an no notching DIN Cf56E2 Improved chip control between -NF3 Rm= N/mm² Bearing Ring -NF3 WPP10 -FP5 WPP10S 140% pos vs.-fp5. More process reliability FP5 DIN 42CrS4+QT Ball joint Prototyp WPP10 -FP5 WPP10S 138% pos Chip control and surface finish C56E2 Flansch -NM4 WPP20 -MP3 WPP10S 250% pos Good chip control 38MnV6 Hub -NM4 WPP20 -MP3 WPP10S 171% pos St24 Fly wheel -NMT WPP30 -MP3 WPP30S 171% pos C56E2 Flansch -NM6 WPP10 -MP3 WPP10S 167% pos Good chip control, reliable DIN EN-GJS Shaft rotor -NR4 WSM20 -MP3 WPP10S 140% pos SAE/AISI 4320 ball joint VW -NS6 WPP10 -MP3 WPP10S 109% pos 100Cr6 Ring -NMT WPP10 -MP3 WPP10S 100% pos same tool life but better chip control 31CrMoV9 Piston -NM4 WPP05 -MP3 WPP10S 67% neg 110Cr6 Outer ring -NM5 WAK20 -MP5 WPP10S 180% pos much better chip control DIN 42CrMo4 Lenkkranz -NM4 WPP20 -MP5 WPP20S 167% pos 16MnCr5 Kupplung -NM4 WPP20 -MP5 WPP30S 140% pos 16MnCr5 Coupling body -NM4 WPP20 -MP5 WPP30S 140% pos better chip control 20MnCrS5 Drive shaft -NM4 WPP20 -MP5 WPP20S 100% equal DIN 31CrMoV9 Rm=1100N/mm² shaft -NM5 WAK20 -RP5 WPP20S 288% pos Chip control better CF53 & 20MnCr5 Hub -NM9 WPP30 -RP5 WPP30S 200% pos DIN Remarks: EN-GJS Shaft rotor -NM4(A) WSM20 -RP5 WPP20S 167% pos Process reliability, Interrupted cut DIN 16MnCr5 shaft -NM5 WAK20 -RP5 WPP20S 147% pos Chip control better DIN Cf53 Kugelnabe -NM9 WPP30 -RP5 WPP30S 147% pos Strong improved chip control with the FP5 and MP3 Geometries. Also tool life results with GG25 Bearing shield WAK10 -RP5 WPP10S 140% pos Process reliability, Interrupted cut GGG50 WPPS are good Fly wheel against the -NM5old grades. WAK20 -RP5 WPP10S 133% pos 16MnCr55 Cilinder -NM4 WSM30 -RP5 WPP20S 100% pos PR / SVPR: 6 January 2012 VM Kussmaul

7 Field test results against Kennametal Material: Workpiece / component: Reference Geometry Reference grade Geometry Walter Grade Walter Difference Walter [%] Result Remarks: 42CrMo4-50CrMo4 Injektorkörper -FN/FF/FP KCP05 -FP5 WPP10S 100% pos 20MnCr5 Sonnenrad -MN KC9110 -MP3 WPP10S 250% pos C56E5 Flange -RN KCP10 -MP3 WPP20S 200% pos C45 Field Test -FN KCP25 -MP3 WPP20S 91% neg Very good chips, tool life can be improved even more Result received only as detailed E- mail. Mat.-Nr PIN -MG KC935 -MP5 WPP10S 125% pos C45 Flange -MN KCP25 -RP5 WPP20S 120% pos good chip control C45 Shaft -RP KCP25 -RP5 WPP10S 110% pos Walter insert was DNMG GG15 Bearing shield -UN KCK15 -RP5 WPP10S 77% neg PR / SVPR: Remarks: Attack first the old steel Turning grades KC91XX, since they have a lower performance, but a lot of customers are still using them. Attack also Beyond grades especially in the lab we saw a not always consistent performance. 7 January 2012 VM Kussmaul

8 Field test results against Seco Material: Workpiece / component: Reference Reference Geometry Grade Geometry grade Walter Walter Difference Walter [%] Result Remarks: PR / SVPR: Mat.100Cr6 Camshaft CP 4 -M5 TP3500 -NM9 WPP30S 200% pos 100Cr6 Outer ring -MF2 TP1500 -FP5 WPP10S 150% pos much better chip control 16MnCr5 Planetary gear -MF2 TP1500 -FP5 WPP10S 150% pos much better chip control 100Cr6 camshaft CPN5 -M5 TP3500 -RP5 WPP20S 120% pos S45C Rack end ball joint -M5 TP500 -MP3 WPP10S 100% pos MP3 showed better chip control, cutting speed was increased in 17% Remarks: Duratomic grades are most probably the strongest competitors right now (Lab tests), but in the areas of the flank wear Walter has a huge advantage. 8 January 2012 VM Kussmaul

9 Feldtestergebnisse gegen Mitsubishi Workpiece / Reference Reference Geometry Grade Difference Material: component: Geometry grade Walter Walter Walter [%] Result Remarks: DIN C45 (Rm=835- Nabe Customer said we have a much 950N/mm²) No SA/-MP UE6110 -FP5 WPP10S 222% pos better chip control. Mat.41CrV4 axle -?? UE6110 -FP5 WPP10S 200% pos Chip control + surface finish SAE/AISI 4320 Rm=1000N/m m² 42CrMoS4 Pinion- RS240 (Ford) -SH UE6105 -FP5 WPP10S 158% pos Steering knuckle -GH UC5115 -RP5 WPP10S 182% pos Better chip control with -FP5 vs. SH.Walter s insert presented more regular wear than the competitor,after 95pcs against 60pcs PR / SVPR: Remarks: Not only tool life also chip control we could improve in a lot of cases. 9 January 2012 VM Kussmaul

10 Field test results against other competitors Competit Workpiece / Reference Reference Geometry Grade Difference or Material: component: Geometry grade Walter Walter Walter [%] Result Remarks: Ceratizit St24 Fly wheel -TM CTC1135 -FP5 WPP20S 171% pos Kyocera 27Mc5 Carrier -HQ CA5525 -MP3 WPP20S 183% pos Kyocera 9SMnPb30 Screw 1 -HT CA5515 -MP5 WPP10S 150% pos PR / SVPR: Kyocera 9SMnPb30 Screw 2 -HT CA5515 -MP5 WPP10S 141% pos Kyocera 9SMnPb30 Screw 3 -HT CA5515 -MP5 WPP10S 141% pos Safety , Flange -7B OR2500 -MP3 WPP20S 187% pos Sumitomo C45 Coupling -SA&-MP UE6110 -FP5 WPP10S 278% pos Sumitomo C50E Hollow wheel -NMP AC830P -MP3 WPP10S 200% pos Sumitomo 4140 Pinion -ESU AC830P -MP3 WPP20S 100% equal Valenite TMS Pinion gear 2 -M MP3 WPP20S 300% pos Valenite TMS Pinion gear 3 -M MP3 WPP20S 300% pos Valenite TMS Pinion gear 1 -M MP3 WPP20S 225% pos Z100.DKW10 ZCCT Cutting wheel -DF YBC152 -FP5 WPP10S 600% pos ZCCT DIN CK45 Shaft rotor -DM YBC152 -RP5 WPP10S 208% pos good chip control, but flank wear comparable to Sumitomo Remarks: 10 January 2012 VM Kussmaul

11 Average tool life increase 163% Tiger tec Silver 100% Competitor Summary: 63% average tool life increase which does not even consider the additional productivity increase in a lot of cases. Maximum tool life increase + 600% 91% of the tests we won In 33% of the tests we could improve big times the chip control Really good results we achieved on forged components with the MP3 and FP5 geometry in the Automotive industry. 11 January 2012 VM Kussmaul

12 Tiger tec Silver - ISO P Generation Turnover pieces 08/ /2012 *Forecast 12 January 2012 VM Kussmaul

13 Table of content 1. General Information TigerTec Silver Results Main features / Difference 2. Geometry MP5 / RP5 Product description Lab tests Field tests 3. Sales information General Handbook 13 January 2012 VM Kussmaul

14 Complete geometry family FP5 Dokončení Oceli MP3 Střední obrábění Oceli s dlouhou třískou MP5 Střední obrábění Oceli obecně RP5 Hrubování Oceli 14 January 2012 VM Kussmaul

15 Geometry MP5 Univerzální, stabilní 3-bodový lamač Od přerušovaných po čisté řezy Vyztužený utvařeč v oblasti rádiusu Vylepšená kontrola lámání třísky pro malé Ap Zvýšení životnosti / snížení opotřebení Otevřený utvařeč na hlavním ostří Jemný řez i při velké hodnotě Ap 15 July 2011 VM Drobniewski Kußmaul

16 Application area MP5 Střední obrábění ocelí obecně Univerzální geometrie pro velký rozsah odlišných ocelí Největší rozsah lámání třísky ze všech vbd Od dlouhých čistých řezů po přerušované řezy Nejprodávanější vbd pro obrábění ocelí-první volba Průmysl Obecné obrábění Job shops Dealeři tuto geometrii milují... také pro velkoseriovou výrobu Typické parametry ap: 0,8 5,0mm f: 0,20 0,60mm 16

17 Evolution NM4 to MP5 NM4 Tighter chip groove - Radius Larger, more stable chip breaker elements for longer tool life and also they do net get washed out. MP5 17 January 2012 VM Kussmaul

18 Evolution NM4 to MP5 Universal, stable three center curve design on both inserts. MP5 NM4 18 January 2012 VM Kussmaul

19 Geometry MP Additional chip breaking area of the MP5 in comparison the NM4 geometry January 2012 VM Kussmaul 19

20 Geometry RP5 Stabilní, positivní 3 fazeta Hrubování s menším řezným odporem Otevřený, hlubší a širší utvařeč Nízká teplota při obrábění Redukované opotřebení v porovnání s předchozími geometriemi Širší fazeta ve střední části hlavního ostří Prevence proti vyštipování při obrábění kovaných obrobků 20 July 2011 VM Drobniewski Kußmaul

21 Application area - RP5 Hrubování ocelí Hrubování s velkou hloubkou Ap a posuvu Redukce opotřebení díky novému designu Obrábění s přerušovanými řezy Rozšířená aplikační oblast: Obrábění GGG ocelolitin jako alternativa k NM5 WAK20 se sortou WPP10S Vyšší povlak WPP10S přináší výhodu když bojujete s opotřebením boku při středních hodnotách Vc Průmysl Power Generation Velkoseriová výroba, např automobilový průmysl, typicky kované hřídele kde F r/2. Obecné obrábění Typické parametry: ap: 2,5 9,0mm f: 0,25 0,90mm 21

22 Geometry RP Additional application area of the RP5 in comparison to the NM9 geometry 22 January 2012 VM Kussmaul

23 RP5 vyvinuto pro delší životnost NM9 Geometrie RP5 Geometrie T = 0,068 mm T = 0,110 mm 23 January 2012 VM Kussmaul

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25 Optimální životnost - součásti Sekvence pro optimalizaci: 1. Maximalizovat hloubku třísky (ap) redukce počtu řezů 2. Maximalizovat posuv (f) Snížení času kontaktu 3. Upravit řeznou rychlost (Vc) Redukce: menší opotřebení Zvýšení: Vyšší produktivita Teplota obrábění / opotřebení Vc: řezná rychlost f: posuv Pravidlo palce: Redukce řezné rychlosti o 10% a zvýšení posuvu o 10% způsobí zvýšení životnosti o cca 20% ap: hloubka třísky Zvýšení ap, f, Vc 25 January 2012 VM Kussmaul

26 Table of content 1. General Information TigerTec Silver Results Main features / Difference 2. Geometry MP5 / RP5 Product description Lab tests Field tests 3. Sales information General Handbook 26 January 2012 VM Kussmaul

27 Available Tiger tec Silver inserts i-pac12-1 Available or will be available by i-pac12-1 i-pac12-1 NRF NRR Step 1: i-pac11-2 Step 2: i-pac12-1 Step 1: i-pac11-2 Step 2: i-pac12-1 Step 1: i-pac12-1 Step 2: i-pac12-2 Step 1: i-pac12-1 Step 2: i-pac12-2 FP5 MP3 MP5 RP5 27 January 2012 VM Kussmaul

28 Competitor information ISO Classification Walter Valenite Coromant Sandvik Kenna metal Widia Seco Tools Mitsubishi Carbide Sumitomo Electric Iscar Tungaloy Kyocera Safety TaeguTec Ceratizit P01 WPP01 VP1505 GC1515 KCP05 TN7005 TN7105 TT1300 P05 WPP05 VP1510 GC4005 GC4205 KC9105 KCP10 TP0500 UE6005 UE6105 AC05A AC700G T9005 CA5505 P10 WPP10 WPP10S VP5515 VP5615 GC4015 GC4215 KC9110 TN7010 TN7110 TP1000 TP1500 UE6110 UE6010 UC6010 ACZ310* AC1000 AC810P IC9015 IC9150 IC8150 T9015 T9115 CA5515 CR7015 OR1500 TT1300 TT1500 CTC1110 P P20 WPP20 WPP20S VP5525 VP5625 GC4025 GC4225 KC9125 KCP25 TN7015 TN7115 TP2000 TP200 TP2500 UE6020 AC2000 AC820P IC9025 IC9250 IC8250 T9025 T9125 AH710* CA5525 CA5025 CR9025 OR2000 OR2500 OR2550 TT3500 CTC1115 CTC1125 CTCP125 P30 P40 WPP30 WPP30S WAK30 VP5535 VP5635 GC4035 GC4235 KC850 KC8050 KCP30 KC9040 KC9140 KCP40 TN7025 TP3000 TP3500 TP400 TP40 UE6035 AC3000 AC830P IC9054 IC8350 T9035 CA5535 OR3500 OR3550 UH6400 IC9054 OR5000 TT7100 KT450 CTC1130 GM40 Link: Comparison_Table_ISO_Turning_Version_ xls 28 January 2012 VM Kussmaul

29 Sales information Upgrade Strategy of current inserts Current geometry NF3 / WPP NS6 / WPP NMT / WPP NM4 / WPP NM9 / WPP NM6 / WPP NMT / WS10 / WSM Upgrade product FP5 / WPPS MP3 / WPPS MP3 / WPPS MP5 / WPPS RP5 / WPPS RP5, further tests are needed for a final decision Stays in the program Upgrade strategy: Price list 2013 with low sales volume will be phased out Price list 2014 additional articles 29 January 2012 VM Kussmaul

30 Sales information Promotion activities Tiger tec Silver BOW Promotion Žádná globální promotion každá WSC si bude dělat promotion sama Kup 20 dostaň 30 Geometrie: FP5, MP3, MP5, RP5 Start květen Info lokální marketink 30 January 2012 VM Kussmaul

31 Sales information Promotion activities Tiger tec Silver Consumer Box 4 Geometries To explain it at the customer Show and Tell Distribution April 2012 Please contact your local Marketing 31 January 2012 VM Kussmaul

32 Sales information Promotion activities Tiger tec Silver Hand Book Tiger tec Silver - ISO P Generation Included Geometries FP5 MP3 MP5 RP5 NRF NRR Please note the complete program is in the hand book included - WPP05S and big Inserts of the MP5/RP5 geometries from i-pac12-2. Available approx. April 2012 Please contact your local Marketing 32 January 2012 VM Kussmaul

33 Sales information Sales documents Product innovation 12-1 Sales start 01. Januar 2012 RP5 Step April 2012 / i-pac12-1 MP5 Step 1 FP5 Step 2 MP3 Step Oktober 2012 / i-pac12-2 MP5 Step 2 (IC bigger 12,7mm) RP5 Step 2 (IC bigger 12,7mm) Remarks: Some line items are maybe available earlier VM-Marketing informs. Price See PDF price list supplement 33 January 2012 VM Kussmaul

34 34 January 2012 VM Kussmaul