CERATIZIT’s UP2DATE solutions for micromachining, milling titanium, finishing steel - Today's Medical Developments

CERATIZIT’s semiannual UP2DATE catalog of product developments and enhancements is now available with the latest offerings designed to give CERATIZIT customers improved machining performance, increased tool life and optimal production efficiency.

Included in the fall 2024 UP2DATE edition are AluLine - Micro milling cutters, the MaxiMill—211-DC, and Cermet inserts.

Micro milling cutters for complex miniature partsCERATIZIT has added to its AluLine Series to meet industry demands for smaller workpieces.

As part sizes get smaller, tolerances play an increasingly key role. With the completely new AluLIne - Micro, high-precision machinists can rely on the pinpoint accuracy of milling cutters with 3µm at 0.2mm diameter. The 4mm tool shank, compatible with shrink-fit holders, adds to high-precision accuracy by ensuring optimum concentricity and the highest contour quality for components. CERATIZIT uses an ultra-fine grain substrate for the new AluLine - Micro milling cutters, which is recommended for use in abrasive aluminum alloys.

Machining aluminum is often associated with sticky chips and built-up edge formations. To address this challenge, AluLine - Micro milling cutters have been outfitted with a special polishing grind that enables more homogeneous cutting edges and significantly improves chip

flow. In addition, the micro milling cutters now feature an ultra-smooth DLC coating. DLC combined with the special geometry of the tools mean sticky aluminum chips are easily removed from the cutting zone.

DLC coatings are extremely advantageous as they can be applied as thin coats so they do not impair the delicate geometries and sharp cutting edges. DLCs also give AluLine - Micro milling cutters a considerable increase in performance and tool life – two essential factors for stable and economical processes.

CERATIZIT’s AluLine - Micro portfolio is extensive. Ranging from radius and torus milling cutters to end mills with corner chamfer, they come in various shank versions, different lengths, geometries and diameter ranges from 0.2mm to 3.0mm or from 3xD to 15xD projection length.

The cool way to machine titanium alloysThe additively manufactured MaxiMil—211-DC indexable insert milling system with advanced coolant supply was developed specifically for heat-resistant materials such as titanium and other super alloys.

For heat-resistant materials, conventional milling systems are limited and unpredictable. The MaxiMil—211-DC was created through in-house additive manufacturing with 3D-printed cooling channels. Additive processes allow the patented shoulder mill to funnel the maximum amount of coolant directly on the insert flanks. In turn, it provides process reliability when machining heat-resistant super alloys.

The MaxiMil—211-DC has 60% longer tool life compared to tools with standard cooling. Further, despite the complexity of the coolant holes inside the tool body, the MaxiMil—211-DC is compatible with standard adapters with through-coolant supply without requiring any standard coolant on the chip breaker.

Finishing strong for steelOne of the most effective ways of optimizing unit costs when finishing steel is to use cermet inserts. The composite material inserts offer heat resistance, increased cutting data and shorter processes. Operators also benefit from the inserts’ dimensional accuracy and long tool life. With the new CTEP110-P cermet grade from CERATIZIT, benefits increase by adding the high-performance DRAGONSKIN coating with wear detection.

To deliver customers even more flexibility in steel finishing, CERATIZIT revamped its portfolio of coatings solutions. CERATIZIT is one of the few manufacturers to offer CVD-coated cermet inserts. CVD-coated cermet offers enormous advantages over PVD coatings for the finishing of steels, including higher temperature resistance and improved wear resistance in the turning process. Furthermore, CVD-coated cermet inserts cover a wider range of applications and are ideal for dry machining. Cermet inserts also excel in delivering smooth workpiece surfaces, producing an exceptional shine, while simultaneously satisfying tight tolerances.

CERATIZIT optimized the new multi-layer DRAGONSKIN coating for cermet grade CTEP110-P, to ensure improved wear resistance and toughness. CERATIZIT also reduced the grain sizes within the individual coating systems and reinforced bonding layers of the new DRAGONSKIN coating to help prevent chipping.

In addition, the cermet grade CTEP110-P features insert detection, which empowers machine operators to easily identify wear and tear on the cutting edges. In turn, operators can ensure every cutting edge on the indexable insert is used.

Because of its four chip grooves, the new cermet grade CTEP110-P is a versatile tool for medium and finishing operations, while ensuring optimum chip control—no matter how fine the cutting depth. Moreover, the range includes two negative indexable inserts, the CF20 and the TFQ. While the CF20 provides precise finishing with sharp finishing geometries at low cutting forces, the TFQ delivers the master finish geometry with very high feed rates and high surface finishes.

Two positive indexable inserts are also available. First, the peripherally ground sharp finishing geometry CF05 delivers high surface qualities in all common steel materials, stainless steels and cast iron even with low cutting forces. Rounding out the range is the CF55, which combines excellent chip control with low cutting forces on all surfaces, even stainless steels.

Download the interactive fall 2024 UP2DATE catalog.