Case Studies: Truck and Bus Applications

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Material: Nodular cast iron (GGG) (SMG K4)
Coolant: Water-soluble oil
Operation: Tapered bore finishing
Criterion: Hole quality
Fixturing: Hydraulic clamping fixture
Tool: Bifix with guide pads
Insert 1: Long special blade 120 mm, +12° CP20

Cutting Data:

	N	v_c	f	f_z	a_p	v_f
Metric	63 rpm	8 m/min	0.8 mm/rev	0.8 mm	105 mm	50 mm/min
Inch	63 rpm	50 sfm	.031 ipr	.0031"	4.13"	1.96 ipm

Results: Hole geometry and machining time improved

Material: Nodular cast iron (GGG) (SMG K4)

Coolant: Water-soluble oil

Operation: Interpolate the retaining ring groove in the bearing bore

Criterion: No burrs allowed

Fixturing: Hydraulic clamping fixture

Tool: Custom grooving cutter

Insert 1: Custom grooving insert CP500

Cutting Data:

	N	v_c	f_z	a_p	v_f	Z
Metric	1293	256 m/min	0.1 mm	7 mm	776 mm/min	6
Inch	1293	937 sfm	.0039"	.275"	30.55 ipm	6

Results: Burrs removed during machining due to proiled insert geometry

Material: Nodular cast iron (GGG 50) (SMG K4)

Coolant: Water-soluble oil

Operation: Reaminig ball bearing bore

Criterion: Hole geometry and surface finish

Fixturing: Hydraulic clamping fixture

Tool: Custom Bifix reamer

Insert 1: P4-EN5-06-CP20

Cutting Data:

	N	v_c	f	f_z	a_p	v_f
Metric	530 rpm	120 m/min	0.25 mm/rev	0.25 mm	0.2 mm	132.5 mm/min
Inch	530 rpm	392 sfm	.01 ipr	.01"	.0078"	5.19 ipm

Results: Improved both component quality (roundness, straightness) and surface finish by 30%

Material: Nodular cast iron (GGG) (SMG K4)

Coolant: Water-soluble oil

Operation: Face milling

Criterion: Tool life

Fixturing: Hydraulic clamping fixture

Tool: Straddle mill Ø 250

Insert 1: LNKT080524PPTN-M06, MK1500

Cutting Data:

	N	v_c	f	f_z	a_p	ae	v	f_z
Metric	351 rpm	276 m/min	2.34 mm/rev	0.13 mm	3 mm	55 mm	821 mm/min	18
Inch	351 rpm	902.5 sfm	.092 ipr	.0051"	.118"	2.16"	32.32 ipm	18

Results: Tool life improved by 33%

Material: Nodular cast iron (GGG) (SMG K4)

Coolant: Water-soluble oil

Operation: Roughing & semi-finishing of bearing bore

Criterion: Reduce machining time

Fixturing: Hydraulic clamping fixture

Tool: Custom multi-step boring bar

Insert 1: SNMG120412-M5, TK2001 (roughing)

Insert 2: SNMG120408-M3, TP1500 (semi finishing)

Cutting Data Insert 1:		N	v_c	f	f_z	a_p	v_f
	Metric	799 rpm	226 m/min	1.2 mm/rev	0.3 mm/rev	3 mm	959 mm/min
	Inch	799 rpm	739 sfm	.047 ipr	.011 ipr	.118"	37.75 ipm
Insert 2:		N	v_c	f	f_z	a_p	v_f
	Metric	865 rpm	250 m/min	0.5 mm/rev	0.25 mm/rev	1 mm	432 mm/min
	Inch	865 rpm	817.5 sfm	.019 ipr	.0098 ipr	.039"	17 ipm

Results: Tool change time reduced due to combined tool for step boring & milling

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