Smooth-running 33% faster
Machining two internal bearing seats on a Hüller Hille NBH 800 horizontal machining center.
The challenge: achieving higher productivity despite an extreme cantilever of 500 mm.
Cross-toothed with tangential 4-edged inserts and narrow tooth pitch … ensure a smooth operation, resulting in a high-quality surface finish and an increased chip volume »Q«
KAMAT is an expert in high-pressure technology. The company, based in Witten with around 100, develops and manufactures plunger pumps for applications with pressures of up to 3500 bar and power outputs of up to 1500 kW. The high-pressure pumps and pump systems are used in almost all industrial sectors. Aquaculture, the food and paper industry, industrial cleaning, mining and the steel industry. The main areas of application are hydraulics, media transport, jetting, decoating, descaling and hydrostatic testing.
The task:
speeding up machining with an extended cantilever
During the descaling process, high-pressure water is used to remove and completely eliminate scale from material surfaces.
The project involved machining two internal bearing seats in gearbox housings made from lamellar graphite cast iron (GG30) on a Hüller Hille NBH 800 horizontal machining center.
A high degree of precision and surface quality was required. Due to the position of the bearing seats, a tool holder with a 500mm cantilever was necessary.
The Task: Optimize machining time.
Previous status:
dimensionally stable, but too long running times
The previously used side milling cutters, with a diameter of 200 mm, delivered high-quality results. However, the extreme cantilever – prone to vibrations – caused the process to take over 21 hours, which was too long under such challenging conditions.
Current status:
highly positive inserts and tangential design to more »Q«
The EN18 side milling cutter, also with a diameter of 200 mm, is the solution for more productive machining. The 4-edged EN indexable inserts in SKY77 quality guarantee a secure and reliable cutting process.The tangential arrangement of the 2 x 9 teeth allows a narrow tooth pitch. The cross-tooth design makes the side milling cutter extremely smooth-running.
As a result, the chip volume for roughing and finishing the bearing seats was increased and machining time was reduced by 33%.
Cross-toothed with tangential 4-edged inserts and narrow tooth pitch … ensure a smooth operation, resulting in a high-quality surface finish and an increased chip volume »Q«
Thomas Oppitz, Production Manager KAMAT (left) and Hans-Georg Nondorf, Area Sales Manager Avantec in NRW (right)
»If a tool can improve process productivity by a third, that’s a significant statement. What Avantec presented to me as a solution was exactly delivered in practice every day.«
Thomas Oppitz, Production Manager KAMAT
Smooth-running 33% faster
Despite the 500mm long cantilever, the stable and smooth-running side milling cutter EN18 ensures high precision and maximum chip volume »Q«. As a result, KAMAT increases the chip volume and therefore productivity by 33%.
The raw blanks of the gearbox housing. The material is cast iron with lamellar graphite (GG30).
The production at Kamat. The gearbox housings are machined with the innovative Avantec solution on a Hüller Hille NBH 800 horizontal machining center.
Tool Tech
Workpiece: gearbox housing
Material: material 0.6030 | GG 30 | EN-GJL-300
Operation: machining of two internal bearing seats
Tool: EN18 side milling cutter with Ø 200 mm and 2×9 cutting edges
Cutting data on request
Shortcut
User: KAMAT GmbH & Co. KG
Sector: high-pressure pumps and systems
Process: cast machining | gearbox housing
Machining with an extended tool cantilever for
internal bearing seats
Focus: optimize machining time
Ensure a reliable automated process
Solution: increase chip volume »Q«
Result: 33% faster machining