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
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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
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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
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© 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
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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
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January 2012
| VM | Kussmaul
© by Walter AG
