Tiger·tec® Silver - ISO P Generation The Rocket

i-PAC12-1
Tiger·tec® Silver - ISO P Generation
The Rocket
1
© by Walter AG
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results competitors
Valenite; 3
Sumitomo; 3
Ceratizit; 1
ZCCT; 2
Safety; 1
Coromant; 26
Mitsubishi; 4
Coromant
Walter
Kennametal
Seco
Kyocera
Kyocera; 4
Mitsubishi
Sumitomo
Valenite
Seco; 5
ZCCT
Ceratizit
Safety
Kennametal; 8
Walter; 24
3
January 2012
| VM | Kussmaul
Total: 81 Tests
13.01.2012
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results competitors
3; 4%
4; 5%
Wins / Gewonnen
Equal / Gleich
Lost / Verloren
74; 91%
Total: 81 Tests
13.01.2012
4
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results against Coromant
Workpiece /
Material:
component:
Mat.100Cr6
camshaft
C45
Bar
4150 MOD.,
WORM GEAR,
230 - 260 BHN
20MnCr5
Reduction gear
16MnCr5
Reverse shaft
St24
Fly wheel
4150 MOD.
WORM GEAR,
18CrMo4 &
17NiCrMo7
Shaft
12379
Profile roller
20NiCr6 (1.5752) Satelite helic 34
41Cr4
Joint housing
C45
Wheel shaft
26MnB5
Profile sleeve
26MnB6
Profile sleeve
1.57105 (35NC6) Planet Carrier
C56 Forging
Wheel Hub
C45 forging
Sideshaft
C45 forging
Sideshaft
42CD4
Shock absorber
C45
Bar
X19CrNiMo4
Roll spindle
42CrMo4
Remarks: Input shaft
C45
Flange
18CrMo4
Shaft
GC42XX areShaft
currently
18CrMo4
performance.
C45
Flange
5
January 2012
| VM | Kussmaul
Reference
Geometry
-MF
-WF
Reference Geometry Grade
grade
Walter
Walter
GC4215
-FP5
WPP10S
GC4215
-FP5
WPP10S
Difference
Walter [%]
200%
187%
Result Remarks:
pos
pos
-WM
-PF
-MF
-PF
-WM
4215
GC4205
1025
GC4225
4215
157%
150%
150%
150%
133%
pos
pos
pos
pos
pos
-LC
GC4215
-QM
GC4225
-PR
4025
-PF
GC4215
-PM
GC4225
-PM
GC4225
-PM
GC4225
-PR
4245
-PF
4215
-PM
4235
-QM
4225
-PM
GC4225
-PR
GC4205
-WMX
GC4225
-PM
GC4225
-PM
GC4225
-PM
GC4215
the
grades
-PFoldestGC4215
-PM
GC4225
-FP5
-FP5
-FP5
-FP5
-FP5
-FP5
-FP5
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP5
-RP5
-RP5
from
-RP5
-RP5
WPP20S
WPP10S
WPP10S
WPP20S
WPP20S
WPP20S 125%
WPP10S 100%
WPP20S 200%
WPP10S 200%
WPP10S 140%
WPP20S 133%
WPP20S 133%
WPP20S 131%
WPP10S 131%
WPP20S 129%
WPP10S 129%
WPP10S 125%
WPP10S 110%
WPP10S 100%
WPP20S 113%
WPP20S 133%
WPP20S 125%
the
big carbide
WPP10S
125%
WPP20S 120%
PR / SVPR:
much better chip control
Cor vc was 230m/min & f 0,2mm /
pos
Walter vc was 250m/min and f 0,25
equal
pos
pos
pos
much better chip control
pos
pos
pos
pos
good chip control
pos
good chip control
pos
good chip control
pos
pos
equal
pos
Better chip control with -MP5 vs. -PM
pos
pos
companies
and
have/ Walter
a weak
pos
Cor Vc
240m/min
Vc270m/min
pos
Cor insert radius 1,6mm / Walter 1,2mm
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results against Walter „old“
Workpiece /
Material:
component:
41CrS4 vergütet
Rm(1000N/mm2)
Ventigehäuse
DIN Cf56E2
Rm=700-800N/mm² Bearing Ring
DIN 42CrS4+QT
C56E2
38MnV6
St24
C56E2
DIN EN-GJS-400-2
SAE/AISI 4320
100Cr6
Ball joint
Flansch
Hub
Fly wheel
Flansch
Shaft rotor
ball joint VW
Ring
Reference Reference Geometry Grade
Geometry grade
Walter
Walter
Difference
Walter [%] Result Remarks:
-NF3
WPP10
-FP5
WPP10S 333%
pos
-NF3
FP5
Prototyp
-NM4
-NM4
-NMT
-NM6
-NR4
-NS6
-NMT
WPP10
-FP5
WPP10S 140%
pos
WPP10
WPP20
WPP20
WPP30
WPP10
WSM20
WPP10
WPP10
-FP5
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
-MP3
WPP10S
WPP10S
WPP10S
WPP30S
WPP10S
WPP10S
WPP10S
WPP10S
pos
pos
pos
pos
pos
pos
pos
pos
138%
250%
171%
171%
167%
140%
109%
100%
PR / SVPR:
Shorter chips an no notching
Improved chip control between -NF3
vs.-FP5. More process reliability
Chip control and surface finish
Good chip control
Good chip control, reliable
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
Remarks:
DIN
EN-GJS-400-2 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 WPP10S
MP3 Geometries.
Also
tool life results with
GG25
Bearing shield
-NM5
WAK10
-RP5
140%
pos
Process reliability, Interrupted cut
WPPS are good
against the
GGG50
Fly wheel
-NM5old grades.
WAK20
-RP5
WPP10S 133%
pos
16MnCr55
Cilinder
-NM4
WSM30
-RP5
WPP20S 100%
pos
6
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results against Kennametal
Material:
Workpiece / Reference Reference Geometry Grade
component: Geometry grade
Walter
Walter
Difference
Walter [%] Result Remarks:
42CrMo450CrMo4
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
Mat.-Nr.
1.2323
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 DNMG150612
GG15
Bearing
shield
-UN
KCK15
-RP5
WPP10S 77%
neg
PR / SVPR:
Very good chips, tool life can be
improved even more
Result received only as detailed Email.
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results against Seco
PR / SVPR:
Material:
Workpiece /
component:
Reference Reference Geometry Grade
Geometry grade
Walter
Walter
Difference
Walter [%] Result Remarks:
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Feldtestergebnisse gegen Mitsubishi
Material:
DIN C45
(Rm=835950N/mm²)
Mat.41CrV4
Workpiece /
component:
Reference Reference Geometry Grade
Geometry grade
Walter
Walter
Nabe
No.313369002 -SA/-MP
axle
-??
SAE/AISI 4320
Rm=1000N/m Pinion- RS240
m²
(Ford)
-SH
Steering
42CrMoS4
knuckle
-GH
Difference
Walter [%] Result Remarks:
UE6110
UE6110
-FP5
-FP5
WPP10S 222%
WPP10S 200%
pos
pos
UE6105
-FP5
WPP10S 158%
pos
UC5115
-RP5
WPP10S 182%
pos
PR / SVPR:
Customer said we have a much
better chip control.
Chip control + surface finish
Better chip control with -FP5 vs. –
SH.Walter´s insert presented more
regular wear than the
competitor,after 95pcs against
60pcs
Remarks:
Not only tool life also chip control we could improve in a lot of cases.
9
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Field test results against “other” competitors
Competit
or
Ceratizit
Kyocera
Kyocera
Material:
St24
27Mc5
9SMnPb30
Reference Reference Geometry
Geometry grade
Walter
-TM
CTC1135 -FP5
-HQ
CA5525
-MP3
-HT
CA5515
-MP5
Grade
Walter
WPP20S
WPP20S
WPP10S
Kyocera
9SMnPb30
Screw 2
-HT
CA5515
-MP5
WPP10S 141%
pos
Kyocera
9SMnPb30
Screw 3
-HT
CA5515
-MP5
WPP10S 141%
pos
Safety
1.7218,
Flange
-7B
OR2500
-MP3
WPP20S 187%
pos
Sumitomo C45
Coupling
-SA&-MP UE6110
-FP5
WPP10S 278%
pos
Sumitomo C50E
Hollow wheel -NMP
-MP3
WPP10S 200%
pos
AC830P
Difference
Walter [%]
171%
183%
150%
PR / SVPR:
Workpiece /
component:
Fly wheel
Carrier
Screw 1
Result Remarks:
pos
pos
pos
AC830P
-MP3
WPP20S 100%
good chip control, but flank
wear comparable to
equal Sumitomo
Pinion gear 2 -M3
5625
-MP3
WPP20S 300%
pos
Pinion gear 3 -M4
5626
-MP3
WPP20S 300%
pos
5625
-MP3
WPP20S 225%
pos
ZCCT
TMS 63002 Pinion gear 1 -M3
Z100.DKW10
.08.02
Cutting wheel -DF
YBC152
-FP5
WPP10S 600%
pos
ZCCT
DIN CK45
YBC152
-RP5
WPP10S 208%
pos
Sumitomo 4140
Pinion
Valenite
TMS 63002
Valenite
TMS 63002
Valenite
Shaft rotor
-ESU
-DM
Remarks:
10
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Average tool life increase
163%
Tiger·tec® Silver
Summary:
100%
Competitor
• 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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Turnover pieces 08/2011 – 01/2012
*Forecast
12
January 2012
| VM | Kussmaul
© by Walter AG
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Geometry MP5
Univerzální, stabilní 3-bodový lamač
Æ Od přerušovaných po čisté řezy
Vyztužený utvařeč v oblasti rádiusu
Æ Vylepšená kontrola lámání třísky pro malé Ap
Æ Zvýšení životnosti / snížení opotřebení
Otevřený utvařeč na hlavním ostří
Æ Jemný řez i při velké hodnotě Ap
15
July 2011
| VM | Drobniewski | Kußmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
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
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Evolution NM4 to MP5
Universal, stable three center curve
design on both inserts.
MP5
NM4
18
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec®
Silver - ISO P Generation
Geometry MP5
2
1
1
2
Additional chip breaking area of the MP5 in
comparison the NM4 geometry
19
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Geometry RP5
Stabilní, positivní 3° fazeta
ÆHrubování s menším řezným
odporem
Otevřený, hlubší a širší utvařeč
ÆNízká teplota při obrábění
Æ Redukované opotřebení v porovnání s
předchozími geometriemi
Širší fazeta ve střední části hlavního ostří
Æ Prevence proti vyštipování při obrábění kovaných
obrobků
20
July 2011
| VM | Drobniewski | Kußmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Application area - RP5
•
Hrubování ocelí
•
Rozšířená aplikační oblast:
•
Průmysl
•
Typické parametry:
21
– Hrubování s velkou hloubkou Ap a posuvu
– Redukce opotřebení díky novému designu
– Obrábění s přerušovanými řezy
– 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
– Power Generation
– Velkoseriová výroba, např automobilový průmysl, typicky
kované hřídele kde F ≥r/2.
– Obecné obrábění
– ap: 2,5 – 9,0mm
– f: 0,25 – 0,90mm
© by Walter AG
Tiger·tec®
Silver - ISO P Generation
Geometry RP5
2
1
1
2
Additional application area of the RP5 in
comparison to the NM9 geometry
22
January 2012
| VM | Kussmaul
© by Walter AG
Tiger·tec® Silver - ISO P Generation
RP5 – vyvinuto pro delší životnost
NM9 Geometrie
RP5 Geometrie
T = 0,068 mm
23
January 2012
| VM | Kussmaul
T = 0,110 mm
© by Walter AG
24
© by Walter AG
Sekvence pro optimalizaci:
1. Maximalizovat hloubku třísky (ap)
Æ redukce počtu řezů
2. Maximalizovat posuv (f)
Æ Snížení času kontaktu
3. Upravit řeznou rychlost (Vc)
Æ Redukce: menší opotřebení
Æ Zvýšení: Vyšší produktivita
Pravidlo palce:
Redukce řezné rychlosti o 10% a zvýšení posuvu
o 10% způsobí zvýšení životnosti o cca 20%
Teplota obrábění / opotřebení
Optimální životnost - součásti
Vc: řezná rychlost
f: posuv
ap: hloubka třísky
Zvýšení ap, f, Vc
25
January 2012
| VM | Kussmaul
© by Walter AG
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
© by Walter AG
Available Tiger·tec® Silver inserts
i-PAC12-1
Available or will be available by 01.04.2012
i-PAC12-1
NRF
Step 1: i-PAC11-2
Step 2: i-PAC12-1
FP5
27
January 2012
| VM | Kussmaul
Step 1: i-PAC11-2
Step 2: i-PAC12-1
MP3
Step 1: i-PAC12-1
Step 2: i-PAC12-2
MP5
i-PAC12-1
NRR
Step 1: i-PAC12-1
Step 2: i-PAC12-2
RP5
© by Walter AG
Tiger·tec® Silver - ISO P Generation
Competitor information
ISO
Coromant Kenna
Sandvik
metal
Classification
Walter
Valenite
P01
WPP01
VP1505
GC1515
P05
WPP05
VP1510
GC4005
GC4205
KC9105
KCP10
P10
WPP10
WPP10S
VP5515
VP5615
GC4015
GC4215
KC9110
TN7010
TN7110
P20
WPP20
WPP20S
VP5525
VP5625
GC4025
GC4225
KC9125
KCP25
TN7015
TN7115
P30
WPP30
WPP30S
VP5535
VP5635
P
KCP05
Widia
Seco
Tools
Mitsubishi Sumitomo
Carbide
Electric
Iscar Tungaloy Kyocera Safety TaeguTec Ceratizit
TN7005
TN7105
TT1300
UE6005
UE6105
AC05A
AC700G
TP1000
TP1500
UE6110
UE6010
UC6010
ACZ310*
AC1000
AC810P
TP2000
TP200
TP2500
UE6020
AC2000
AC820P
KC850
KC8050
KCP30
TP3000
TP3500
UE6035
KC9040
KC9140
KCP40
TP400
TP40
TP0500
T9005
CA5505
IC9015
IC9150
IC8150
T9015
T9115
CA5515
CR7015
OR1500
TT1300
TT1500
CTC1110
IC9025
IC9250
IC8250
T9025
T9125
AH710*
CA5525
CA5025
CR9025
OR2000
OR2500
OR2550
TT3500
CTC1115
CTC1125
CTCP125
IC9054
IC8350
T9035
CA5535
OR3500
OR3550
TT7100
KT450
CTC1130
GM40
TN7025
GC4035
GC4235
P40
WAK30
AC3000
AC830P
UH6400
IC9054
OR5000
Link: Comparison_Table_ISO_Turning_Version_012012.xls
28
January 2012
| VM | Kussmaul
© by Walter AG
Sales information
Upgrade Strategy of current inserts
Current geometry
Upgrade product
NF3 / WPP
FP5 / WPPS
NS6 / WPP
MP3 / WPPS
NMT / WPP
MP3 / WPPS
NM4 / WPP
MP5 / WPPS
NM9 / WPP
RP5 / WPPS
NM6 / WPP
RP5, further tests are needed
for a final decision
NMT / WS10 / WSM
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
© by Walter AG
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
© by Walter AG
Sales information
Promotion activities
• Tiger·tec® Silver Consumer Box
–
–
–
–
–
31
January 2012
4 Geometries
To explain it at the customer
„Show and Tell“
Distribution April 2012
Please contact your local Marketing
| VM | Kussmaul
© by Walter AG
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
© by Walter AG
Sales information
•
Sales documents
•
Sales start
– Product innovation 12-1
– 01. Januar 2012
– RP5 Step 1
– 01.
–
–
–
April 2012 / i-PAC12-1
MP5 Step 1
FP5 Step 2
MP3 Step 2
– 01. 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.
•
33
Price
– See PDF price list supplement
January 2012
| VM | Kussmaul
© by Walter AG
34
January 2012
| VM | Kussmaul
© by Walter AG