Case Studies: Ball Bearing Location
Just watch current case studies in automotive industry comparing Ball Bearing Location.Material: Nodular cast iron (GGG) (SMG K4)
Coolant: Water-soluble oil
Operation: O.D. turning, combining inner and outer radius with chamfer
Criterion: Cycle time and tool life
Fixturing: Hydraulic clamping fixture
Tool: Custom O.D. step-turning tool
Insert 1: ACET150631TR-MD14-F40M
Insert 2: SCMT070308-F2, TP40
Insert 3: Altered TPUN22 with special shape F40M
Cutting Data:
| N | vc | f | fz | ap | vf |
| Metric | 1185 rpm | 231 m/min | 0.4 mm | 0.2 mm/rev | 3 mm | 262 mm/min |
| Inch | 1185 rpm | 755 sfm | .0157" | .0078 ipr | .118" | 10.31 ipm |
Results: Cutting speed increased by 20% and tool life increased by 22%
Material: Nodular cast iron (GGG) (SMG K4)
Coolant: Water-soluble oil
Operation: Rough boring bearing location
Criterion: Tool life & cycle time
Fixturing: Hydraulic clamping fixture
Tool: Custom step boring bar
Insert 1: TNMG160408-M5, TK2001
Insert 2: SCMT09T308-M3, TK2001
Cutting Data:
| N | vc | f | fz | ap | vf |
| Metric | 1240 rpm | 300 m/min | 0.7 mm/rev | 0.35 mm | 3 mm | 868 mm/min |
| Inch | 1240 rpm | 981 sfm | .0275 ipr | .0137" | .118" | 34.17 ipm |
Results: Tool life improved by 35% and cutting speed increased by 30%
Material: Nodular cast iron (GGG) (SMG K4)
Coolant: Water-soluble oil
Operation: Bearing housing
Criterion: Tolerance H6, cylindricity=5µ, surface finish Ra=1
Fixturing: Hydraulic clamping fixture
Tool: Multi-tooth indexable reamer Xfix
Insert 1: RNAX-1005-EB45-03, RX2000
Cutting Data:
| N | vc | f | fz | ap | vf |
| Metric | 970 rpm | 250 m/min | 0.9 mm | 0.18 mm | 0.2 mm | 870 mm/min |
| Inch | 970 rpm | 817 sfm | .035" | .007" | .008 | 34 imp |
Results: Tool life increased by 25% and productivity improved
Material: Nodular cast iron (GGG) (SMG K4)
Coolant: Water-soluble oil
Operation: Circlips groove and under cut on ball bearing location
Criterion: Surface finish and no burr
Fixture: Hydraulic clamping fixture
Tool: Multi-tooth custom cutter Ø 68
Insert 1: TCMT110208-F1, TP1500
Insert 2: Custom triangular insert 340 FG
Cutting Data:
| N | vc | fn | fz | vf | z |
| Metric | 1030 rpm | 220 m/min | 0.75 mm | 0.15 mm | 772 mm/min | 5 |
| Inch | 1030 rpm | 720 sfm | .029" | .006" | 30.39 ipm | 5 |
Results: Tool life increased by 25%
Material: Aluminium (AS7) (SMG N1)
Coolant: Water-soluble oil
Operation: Rough boring bearing location
Criterion: Chip control
Fixturing: Hydraulic clamping fixture
Tool: Custom boring bar Ø82 / 92 + chamfer
Insert 1: TCGT160408FAL-KX
Cutting Data:
| N | vc | f | fz | ap | vf |
| Metric | 1384 rpm | 400 m/min | 0.24 mm/rev | 0.12 mm | 3 mm | 332 mm/min |
| Inch | 1384 rpm | 1308 sfm | .00944 ipr | .00472" | .118" | 13.07 imp |
Results: Tool cost per piece reduced and chip control improved