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Shank milling cutters made of solid carbide are very expensive. When manufacturing individual parts or small batch production, many users have abandoned expensive investments and chose high speed steel tools. Another option is Walter's new ConeFit® interchangeable head milling cutter. After testing the tool, Heinrich Betz OHG, a non-standard tool manufacturer in the town of Li?berg (near Ortenberg, Hesse, Germany) immediately incorporated it into its own procurement. Product Range.
If a medium-sized manufacturer with more than 120 employees wants to develop and manufacture parts for high-tech, first-class departments, it must have considerable expertise. Since the 1990s, Heinrich Betz OHG has been providing mechanical parts for systems that produce solar cells and flat panel displays. Its customers are suppliers to large manufacturers of solar cells and flat screen displays in the Far East. Heinrich Betz OHG develops and manufactures products according to customer requirements. The system they use is a cavity system. A plurality of hermetically sealed cavities are combined to form a single production line (as shown in Figures 1 and 2). The largest cavity size is approximately 2.8mx 2.8m. Each cavity is specially sprayed under vacuum or in a specific atmosphere. The sensitive display part moves completely automatically along the processing chain under the action of the knife. In addition to providing important valves, Heinrich Betz also offers a guillotine – a core product developed by Heinrich Betz for several years.
The company has the technology needed to produce cutting-edge components. If you want to be highly competitive in the market, then this is very beneficial to the company. Gert Minnert, the leader of the process technology department, stressed: “Our business scope covers all industries, while meeting all the requirements of mechanical engineering and equipment installation engineering, including milling, turning and special processes, such as 4000 Deep hole drilling in millimeters or machining of large parts up to 14 meters in length. Also includes modern welding methods using gas shielded welding processes or electron beam welding processes." The scope of service indicates that in addition to the industries mentioned above, we can also serve In other industries, such as the packaging industry (see the text in the box below).
Because the high-tech industry in particular requires sophisticated materials, medium-sized companies have a wide range of materials. In addition to a small amount of normal structural steel, many stainless steel, titanium, copper and aluminum are also the main objects of processing. Most of the cavity itself is made of stainless steel. There are also cavities of aluminum construction.
Successful trial for the first time
Heinrich Betz has previously used a shank end mill or ball end mill made of high speed steel HSS-E to machine a circular milling groove with a radius of 8 mm in a valve block made of stainless steel 1.4301 (main part). Because the angular groove of the ball end mill can seriously impair the performance of the part and the cost is high, the solid carbide tool is not considered long ago. A very difficult decision is whether we should accept higher tooling costs. When it comes to solid carbide tools, we need to think twice about this before making a decision. While thinking, you must also consider whether the quantity and machinability of the material and whether other processes will benefit from this decision.
The leader of the process technology department, Gert Minnert and process engineer, Michael Strupp, found another solution: Walter's new ConeFit® solid carbide interchangeable head milling cutter. Various solid carbide milling cutter heads are screwed to low cost steel shanks of different lengths. Special tapered threads on the support surface ensure maximum stability during processing. Two production experts report: "The first initial test was very successful. Therefore, we introduced the 16 mm diameter ball end mill for machining the valve group milling in the "Machine Tool" magazine, according to Walter's It is recommended that this be described. This tool is excellent in practical applications.†The valve block is machined on a German Matec 30L moving column machining center with a swivel head and SK-40 adapter. A powerful chuck provides tension to it.
Walter Technical Consultant, Mr. Wolfgang Taube said: “The transition from high-speed steel tools to ConeFitTM tools offers users a range of benefits. In short, increased depth of cut and feed rate correspondingly reduce machining time.†Let's take a closer look. Five operations were required to machine the valve block before milling, but now only twice. The cutting speed may increase from 50 m/min to 134 m/min and the feed rate increases from 150 mm/min to 975 mm/min. If the total machining length is 300 mm, the machining time for each part is reduced from the previous 10 minutes to the current 36 seconds. Such a huge improvement is mainly due to the reduction in the number of operations. If the planned number of processes is 180/year, the machine operating time (HSS) is reduced from the initial 30 hours to 1.8 hours.
But that's not the case. Although the changeable milling head is made of solid carbide, its cost is still very high. When making a decision, Walter's solution is comparable to high-speed steel tools, making it difficult to choose. The ConeFit® cutter is less expensive because the production is almost doubled (see the text in the box).
Because the products produced by the Tübingen machine tool manufacturer include many other types of milling cutters in addition to the ball end mills, the company with Heinrich Betz can use a wide range of solid carbide tools in the future. The first interchangeable head milling cutter has been used to machine titanium parts. The head of the process technology department also said: "The flexibility of the ConeFitTM tool ensures that it is suitable for many applications. It has higher performance than high-speed steel tools. In addition, it has another benefit, namely total Tool costs are low, so we can quickly answer if we should introduce this tool."
Performance advantages of ConeFitTM tools
Example: A valve block made of material 1.4301. An annular groove with a radius of 8 mm is machined with a ball cutter of D = 16 mm, z = 4 mm. The milling depth is 6 mm. Machine tool: Germany Matec 30L moving column machining center.
System supplier for special purpose machine tool structures
Heinrich Betz OHG (approximately 120 employees), a non-standard tool manufacturer located in the small town of Li berg (near Ortenberg, Hesse, Germany) offers individual parts and special machines. This medium-sized family-owned company was founded in 1901. At the time, they made the tools needed for the watch industry. This company, created by artisans, has evolved over the years into a system supplier for multiple industries. In the 1960s, companies began producing parts that make up pharmaceutical packaging machines. Now they are focusing on the large assembly industry, the renewable energy (solar) industry, and coating technology (flat screen displays). In these respects, the company has become one of the world's leading suppliers. It is characterized by the depth of production. In April 2007, the company developed a new milestone, the establishment of the subsidiary HEVATEC Systeme und Anlagenbau GmbH (Hohenstein-Enstal, Saxony, with about 80 employees).
The company's services include: 4000mm deep hole drilling, manufacturing of large parts (up to 14,000 x 5000 x 5000 mm, part weight 70 tons), measurement of large components, multiple materials (stainless steel, aluminum, copper, Processing of titanium, etc., and the use of modern welding methods (WIG, MAG and electron beam welding processes).
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