Process optimisation thanks to self-checking

Kyocera at METAV 2004

02 June 2004

Few interruptions to production, lower expenditure, high process safety, high productivity – these are important factors which matter in the metal-working industry.

Sensor Tool System Kyocera
Kyocera's Sensor Tool System
At METAV 2004 in Düsseldorf (15 - 19 June, Hall 9, Stand C35) the Japanese technology company, Kyocera, is presenting its wide range of standard and individually tailored cutting tools and components, able to meet these demands. Under the brand name CERATIP Kyocera offers high-quality tool systems which are able to achieve process optimisation and thus economical production. With what is called the Sensor Tool System Kyocera has de-veloped an intelligent indexable insert specially for the auto-mobile industry – for example for manufacturing brake discs.Cost reduction is a prime priority with these tool systems, since the Sensor Tool
System can recognise damage, excessive wear and even microscopic fractures directly on the cutting edge. This triggers a corresponding command which can be sent to the machine control in order to interrupt the process.
While in the case of conventional cutting, the edge is only util-ised up to 70 per cent and, in order for the process to be safe, 30 per cent is designed for use as a safety buffer, the Kyocera indexable insert may be used by the Sensor Tool System up to 100 per cent. Thus huge losses are avoided in the case of high volume mass production.
“A Sensor Tool cutting insert costs about 15 per cent more than a normal silicium nitride indexable insert, but thanks to process optimisation it can achieve cost savings of up to 40 per cent,“ underlines José Agustín-Payá, Manager for Product Marketing and Technology at the Kyocera Cutting Tools Division.

Economy through precision technology for hard turning operations

When compared to the CBN often used in this field, the Kyo-cera mixed ceramics have excellent cutting properties. Through the use of Kyocera mixed ceramics, cutting speed can be increased. While CBN operates at a cutting speed of 150 m/min, with coated Kyocera ceramics speeds of up to 400 m/min can be achieved. This means a higher output per ma-chine and cost savings for each cutting insert.
Moreover the Kyocera ceramics are also more economically priced than CBN, since costs are up to 80 per cent lower.

High potential in terms of economy – also for softmachin-ing steel

Kyocera is known worldwide as one of the leading manufac-turers of the material Cermet. Agustín-Payá considers that the development of this material presents very positive opportuni-ties: “In the metal-working industry at the present time the use of Cermet tools represents only about 6 per cent. If properly used the total potential is 40 per cent.”

Kyocera at METAV 2004: Hall 9, Stand C35