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No. 29April2007
FACTSFACTSCustomer magazine
for coating technology
Boehlerit:
Wohlhaupter GmbH:With SN² for a performance increase of 15x during precision machiningPages 4-5
Seiten 6-7
BESCHICHTETE WENDESCHNEIDPLATTEN
BRINGEN MEHR LEISTUNG
Seco-Jabro Tools:SeparateeasierPages 14-15
Pages 8-9DIAMOND COATED BLADES
CUT MORE SHARPLY
Pokolm:Top inmouldsPages 6-7
Bernd Hermeler,Head of Marketing, Sales & Services
n Editorial 2 n Economic hard machining 3 with HSN² supernitrides Improved surface quality also beyond the 50 HRc limit
n 15-fold performance 4-5 Precision processing of hard materials is optimised with SN²
n Expertise solves mould problems 6-7 Precision moulds for hollow chocolate figures using milling cutters coated with supernitrides
n Sharp, mirror smooth and 8-9 extremely wear resistant Diamond coated blades attain much smoother cutting results in many applications
n Without sticking out of the mould 10-11 High-performance coatings on mould making tools reduce wear and improve mould removal
n Compact systems for 12-13 in-house coating competence The CC800®/9 JET is the cost-effective alternative for small and medium-size vendors
n Light weight construction experts14-15 optimize processes Airbus manufacturing profits from tailor-made coating solutions for aluminium
n Regional Sales ensures rapid 16-18 service for CemeCon customers Throughout Germany customer advisers help to make things run smooth
n Drilling in cast iron is no 19 “difficult case” anymore “Heavy duty” supernitride makes customers fear highly abrasive materials no longer
n Sales partner for the Korean market 20 Customer satisfaction also in the Far East
n Imprint 20
Highest quality owing to bundled expertise
Bernd Hermeler,Head of Marketing, Sales & Services
In this edition
Innovations of yesterday are the standards of today and this also applies in the area of coating technology. For quite a while now, coatings which are frequently only a few micrometres thick decide as to the success of high-performance tools. More and more users are finding that a standard coating does not get the most out of the production process – only tailor-made systems bring about the decisive advantages.
In order to develop application optimised coatings of the high-est quality, expertise is required: a knowledge about substrates, geometries and the corresponding applications are for this an essential requirement. In the past we have already always bundled our expertise in the manufacture and development of coatings. For example, at the headquarters in Würselen, Germany which in the meantime has developed in to one of the largest coating centres worldwide. Here we are implemen-ting through over 45 coating systems also complex requests for user related coating solutions, and this efficiently and promptly. Thus the user is in a position to reproduce the coatings at any time at the highest quality.
A regional sales network close at hand to the customer and a fully developed logistics network, moreover, ensure proximity to our customers as well as short delivery times. At the same time customers profit quickly from the speedy developments in the coating sector: because at CemeCon product manage-ment, product development and production are not only sitting door-to-door, but work next to each other all the faster hand in hand.
Anyone wanting to deposit tailor-made coatings themselves will at CemeCon find a matching solution: upon request we will integrate the entire in-house coating technology in the production workflow. Basis for this are our coating systems CC800®/9 as well as the comprehensive service provided by the CemeCon staff who with their know-how will assist the users almost around the clock.
Also in this edition of FACTS we are presenting numerous ex-amples as to how we cooperate with our customers to make the most of their applications – thanks to groundbreaking technology and uncompromising quality.
I wish you interesting reading of the current edition of FACTS.Bernd Hermeler,Manager Marketing, Sales & Services
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Voha-Tosec: Economic hard machining
Not for “Softies” – Hard, harder, HSN²
Through hard machining of compon-Through hard machining of compon-ents tremendous saving potentials are ents tremendous saving potentials are utilised in production. In many cases it utilised in production. In many cases it will be possible to machine components will be possible to machine components without the need for re-clamping these without the need for re-clamping these and time-consuming electrical discharge and time-consuming electrical discharge machining is avoided. Hard machining machining is avoided. Hard machining cuts production times and also tooling cuts production times and also tooling and cooling lubricant costs. The chips and cooling lubricant costs. The chips which are produced are free of any which are produced are free of any contamination. They may be directly contamination. They may be directly recycled.
Hard machining is highly demanding Hard machining is highly demanding regarding the tools and the coating. regarding the tools and the coating. These are subjected, among other These are subjected, among other things, to high temperatures, cutting things, to high temperatures, cutting speeds of up to 250 m/min or extreme speeds of up to 250 m/min or extreme advance rates of 0.3 millimetres per advance rates of 0.3 millimetres per turn, for example. The tools used must turn, for example. The tools used must withstand these extreme conditions withstand these extreme conditions through a coating which is tailor-made through a coating which is tailor-made in view of the specific application. The in view of the specific application. The multilayer nano-composite HSN² used multilayer nano-composite HSN² used by Voha-Tosec is based on an entirely by Voha-Tosec is based on an entirely new development for hard machining new development for hard machining and has all the prerequisites for attai-and has all the prerequisites for attai-ning best results. Because it is extreme-ning best results. Because it is extreme-ly hard, smooth, temperature resistant, ly hard, smooth, temperature resistant, substantially free of residual stresses substantially free of residual stresses and chemically extremely stable.and chemically extremely stable.
The excellent results attained in practice The excellent results attained in practice speak for themselves. Carsten Klein, speak for themselves. Carsten Klein, Managing Director of the tool manu-Managing Director of the tool manu-
facturer from Lindlar, Germany: “For many years now we are enjoying with CemeCon a close partnership-like rela-
tionship. Always when the need arises to find a special or even difficult solution, we can rely on the coating specialists. Hard machining, just as in the specific case of having to mill cold work steel 1.2767, is a good example of this”. Carbide corner radius milling cutters and as well as ball-head milling cutters coated with HSN² from Voha-Tosec do far better compared to tools coated with conventional hard coatings and even compared to special hard pro-cessing coatings of competitors. For example in the area of wear. Carsten Klein: “Our tool exhibits after 30 hours of use with 0.02 mm compared to 0.03 mm, respectively 0.05 mm significantly much less wear”.
For Voha-Tosec the conversion has paid off. Through tools coated with HSN²
the company is now also on the safe side when it comes to hard machining: shorter processing times, reduced setup and handling times as well as higher quality, cut costs significantly in the end.
Your contact at CemeCon
Manfred WeigandProduct Manager
Round ToolsTel.:
+49 (0) 24 05 / 44 70 135
In 1988, the company Voha
was founded in Lindlar, Germany. With only two staff here the design and deve-lopment of high-performance milling tools made of carbide started which were being used to machine moulds and to manuf-acture machinery and tools. Beginning in 1996, through well focused sales and re-structuring activities, the company expan-ded considerably and installed jointly with the company Tosec Werkzeuge GmbH its own sales organisation. Today a workforce of 17 working on a floor space of over 1000 square metres is responsible for the success of the company Voha-Tosec Werkzeuge GmbH.
Voha-Tosec Werkzeuge GmbHManaging Director: Carsten Klein, Werner Röttel, Dieter ScheurerSchreinerweg 2a + 2b, 51789 Lindlar, GermanyTel.: +49 (0) 22 66 / 47 81 -11 Fax: +49 (0) 22 66 / 47 81 [email protected], www.voha-tosec.de
HSN² comparison
Improved surface qualities, shorter proces-sing times, shorter door-to-door times – hard machining beyond the 50 HRc limit offers tre-
mendous advantages for the machining vendor. HSN² is the response from CemeCon to these extreme requirements. Because only precision tools carrying this innovative coating material make reliable hard machining feasible. The new coating material is based on the second generation superni-trides from CemeCon thereby “degrading to softies” other trides from CemeCon thereby “degrading to softies” other coatings used in the past for hard machining.coatings used in the past for hard machining.
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Inside processing with micrometer accuracy is as such already a challenge for tools and machines. And when also extremely hard materials need to be processed, the combi-ned expertise is much in demand: then tool manufacturer and coating professionals will optimise the solutions which are customised with respect to the specific task – frequently with enormous performance increases:
Wohlhaupter GmbH: Precision processing with a performance increased of 15x
From 6 to 90 with SN² Precision processing of hard materials much stresses the tools being used: high-strength types of steel de-mand everything from these tools and has to be paid for in most cases through strong wear on the tools. In order to render such processing more economic, more and more tool manufacturers are relying on high-performance coating materials – like su-pernitrides from the SN²-class provided by CemeCon.
Process optimisationthrough SN²
At the company Helmut Christmann GmbH from the Swabian town of Birkenfeld there were difficulties regarding processing stabi-lity when precision processing boreholes in precision machined subassemblies made of X153CrMoV12-(1.2379) steel.
Helmut Christmann, Managing Director of Christmann GmbH: “With the tools used to date it was absolutely not possible to precision machine more than six boreholes in one go in this highly wear-resistant type of steel – absolutely inadequate for efficient production. For this reason we talked to the company Wohlhaupter GmbH as one of our tool suppliers. And they had a solution”.
In the development department of the company Wohlhaupter the engineers from Wohlhaupter adapted together with the ex-perts from CemeCon both tools and coa-ting for this particular application – among other things for the miniature turning out cutting edges of the DigiBore tools.
“The results were overwhelming” says Dipl.-Ing. Holger Rabe, head of project management for indexable inserts at Wohlhaupter. “Through the improved process thanks to the SN² coating we can now precision process instead of six bores in the past, now a total of 90 with a single
Modern system technology employed by the Christmann High Precision Team provides the basis for groundbreaking innovations.
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Wohlhaupter GmbH: Precision processing with a performance increased of 15x
turning out cutting edge tool. And this at the highest precision of 2 µm in a single work step”
Micrometer accurateprecision processing in a single work step
Such results have at all only become feasible mostly owing to the extremely smooth surfaces of the TINALOX® SN² coating material. The TINALOX® SN² material allows for per-fect removal of the chips and permits, owing to its high degree of toughness combined with very high hardness, re-liable processing of steel or cast-iron, for
Your contact at CemeCon
Marc SemderSales Europe
Tel.:+49 (0) 171 / 9700 736
+49 (0) 711 / 72 61 090
Christmann High Precision Team:
The Christmann High Precision Team was founded in 1948 and has for 25 years its headquarters in the town of Birkenfeld in the northern part of the Black Forest. In modern facilities and by relying on fully networked CAD/CAM workplaces, the company CHRISTMANN High Precision is constantly creating innovations from the areas of high-performance networ-ked tools, wearing parts for punching operations and mould making, precision machined subassemblies and components as well as complex turned, milled, erosion manufactured parts as well as clamping means for the area of electrical discharge machining. Helmut Christmann GmbHMr. ChristmannCarl-Benz-Straße 975217 Birkenfeld, GermanyTel.: +49 (0) 72 31 / 9 48 82 -0Fax: +49 (0) 72 31 / 9 48 82 [email protected]
Wohlhaupter GmbH:
For 75 years now the Swabian fami-ly-owned company Wohlhaupter has been synonymous for modular precision tooling systems in the area of turning/precision machining as well as groove making, including clamping technology. Groundbreaking developments are, for example, the automatic balancing facility of the BALANCE precision turning heads, the direct displacement measurement with digital readout of the precision tur-ning tool DigiBore or the Combi-Line tool, a drilling head in which roughing and smoothing is performed in a single work step. Highest product quality, full system integration and security of investment are important components of the company’s philosophy which has already paid off by being awarded several innovation prizes. At the Frickenhausen location, a workforce of 170 is attaining
an annual turnover of approximately 23 million �.
WOHLHAUPTER GmbHDipl.-Ing. Holger RabeProject Management Cutting Inserts Maybachstr. 4D-72636 Frickenhausen, GermanyTel.: +49 (0) 70 22 / 408 -142Fax: +49 (0) 70 22 / 408 -177E-Mail: [email protected]
Instead of only 6, now 90 bores can be precision machined: Holger Rabe,
Product Manager for Indexable Inserts at Wohlhaupter (left), and Marcus Christmann, Quality Ma-nagement and Deputy Managing Director of the company Helmut
Christmann GmbH, are much satis-fied with the results.
Managing Director Helmut Christ-mann (right) and his deputy Marcus Christmann.
example. The coating material is the ideal solution for the applications run at the company Christmann GmbH – proven
in an impressive way through the enor-mously extended service life and the resulting production cost savings”. n
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Pokolm Frästechnik: Top in moulds
Twoexperts
in the same boat
At the end of September 2006, the Austrian town of Steyr was again the meeting point of the specialists from the area of high-
The way to the perfect hollow chocolate item is long: for example, precision machined moulds are needed in which the liquid chocolate attains its marked contour. That already the month of September can be the right point of time for Easter bunnies was proven by the company Pokolm Frästechnik GmbH from the town of Harsewinkel, Germany through its first place in the 7th European High Speed Machining Award 2006.
speed machining and precision manufac-turing in order to position themselves, by way of a competition between each
other, even more clearly on the market. 15 companies from the area of „hard milling“ accepted this offer – the company Pokolm Frästechnik from the East-West-phalian town of Harsewinkel was able to win recognition.
A mould insert for a chocolate Easter bunny was to be processed according to the han-
The specialists from Pokolm and CemeCon cooperate closely. This guarantees optimum high-per-formance tools. At the back from the left: Uwe Kaupert, Thorsten Bothe, Thomas Schaaff, Gerhard Maurus, Jürgen Laudenbach, F. J. Pokolm, Be-ate Hüttermann, Markus Grünwald, Rüdiger Jonas. At the front from the left Rolf Lenker, Dirk Varnholt, Sven Rahmlow, Marco Pokolm.
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Pokolm Frästechnik: Top in moulds
The company Pokolm Frästechnik GmbH & Co. KG is a wholly owned family enter-prise: founded in 1994 by Franz Pokolm, his wife and son Marco share the business responsibility. The daughter Tatjana Peters manages and controls the marketing aspects of the company with its workforce of around 60. Since 1997, there exists a cooperation with the company Vollhartmetall-Werkzeuge GmbH (Voha-Tosec) with headquarters in Lindlar, Germany. Pokolm and Voha-Tosec have accordingly also a joint catalogue, present themselves together at exhibitions and supplement their activities in the area of development and production of new tool systems. Already since the beginning of the company Pokolm-Frästechnik, the experts based in the town of Harsewinkel rely on coatings from CemeCon. It is foremost through the precise tuning between metal, geometry and coating that Pokolm time and again comes first in the tough competition as to the best milling strategies.
Contact:Pokolm Frästechnik GmbH & Co. KGAdam-Opel-Straße 533428 Harsewinkel, GermanyTel.: +49 (0) 5247 9361-0Fax: +49 (0) 5247 9361-99freecall Fax 08 00 / 0 76 56 56E-Mail: [email protected]
ded out CAD data. Franz Pokolm, owner of the company Pokolm Frästechnik: “The geometry of the work piece which was to be manufactured was certainly deman-ding: in the case of the Easter bunny of the confectioner Roman Hauswirth from the town of Kittsee we had to mill differently deep and shallow areas – and this of course with a surface quality and accuracy which was to be as high as possible. In the case of X38CrMoV5-1 steel having a hardness of 52 to 54 HRC, it is essential to equip the machines with the matching tools!”
Finest contours withprecision tools
And in this case the tools had to be pre-cise and durable – this at the same time being quite a challenge for the coating vendor. In view of the stringent require-ments, precision tools of the utmost quality were much in demand. Together with the engineers from Pokolm, the ex-perts from CemeCon worked out the corresponding coating solutions based on supernitride coating materials – and this with success.
Contour accuracy in the mould cavity on the entire surface amounted to +/- 0.015 mm, all surfaces exhibited a surface accuracy of 0.3 Ra. This was achieved above all through the corresponding tools – the smallest tool used in connection with the mould cavity exhibited a diameter of just 2 mm. At the separating plane, surface quality was 0.5 to 0.6 Ra and for the contour of the letters 0.8 to 1.0Ra. Franz Pokolm: “Especially the con-tour of the letters was a challenge because these were particularly fine and fragile. For these we used a milling cutter coated with a supernitride and this with a milling cutter diameter of just 1 mm”.
Important quality criteria of this award were, besides complying as best pos-sible with the demanded manufacturing tolerances, the assessment of the visual overall impression and the surface qua-lity of all surfaces. Moreover, the milling respectively processing strategies, the processing time until attaining the surface accuracy in the mould cavity, the separa-ting plane and the lettering as well as the degree of innovation of the submitted proposals were assessed.
Milling at tremendous speed
From the 15 participating companies, the company Pokolm Frästechnik won the first place in the category “hard milling” taking a time of two hours, 29 minutes and 52 seconds.
“Breakdowns caused by a broken tool or a failure of the coating would have cost us the first place. But sound preparation work by the entire team regarding the challenge and to show off our abilities in a competition with other top-class ven-dors, fully paid off” explains Pokolm boss Franz Pokolm who received the award jointly with his son Marco.
After the cooperation for this award was concluded successfully, Pokolm and Ce-meCon are now jointly working already on the next challenge.
Your contact at CemeCon
Thomas SchaaffSales Europe
Tel.: +49 (0) 24 05 / 44 70 125
Much pleased about the prize, from the left: Marco Pokolm, Natalie Pokolm, Franz Pokolm, Sven Rahmlow.
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GFD: At the cutting-edge
Sharp, sharper TopSharp
Thosten Rübben, Mohamed Boubrik, Aydin YildirimTel.: +49 (0) 2405 4470 113; -513; -543
Cutting blades are used in many engi-neering areas. When separating plastic and metal foils as well as paper, but also for cutting of rubber, textiles and leather these are being used. The custo-mers requirements are clear: economic solutions in which a long service life and a high processing speed is obtained and this with optimum cutting edge proper-ties. Depending on the processing task, today blades made of steel, carbide or ceramics are being used. Dr. Andre Flö-ter, Managing Director at GFD: „The re-quirements regarding cutting blades are increasing through adding dyes, white-ning agents, fibre inclusions, compound materials but also through ever increa-sing processing speeds. The previously used blades are rapidly reaching their limits here, wear down all too quickly
At the fakuma 2006 exhibition they were a small sensation – the Diamaze®-PSD (Plasma Sharpened Diamond) blades from GFD, Gesellschaft für Diamantprodukte mbH from Ulm, Germany. Optimised with the CCDia®TopSharp coa-ting from CemeCon these blades are sharp, mirror-smooth as well as extremely wear-resistant.
and become blunt. The result is a more frequent and involved replacement of blades causing corresponding machine downtimes.“
Diamond coating forhigher speeds
The solution is a thin and nano-crystalline diamond coating which already in the area of machining non-iron materials is provi-ding for several years now spectacular re-sults. It provides all important advantages of the natural material: Diamond is not only the hardest known material, it is at a low and medium temperatures almost entirely chemically resistant. It offers the highest known temperature conductance and has – this being of special importance during cutting operations – an extreme-
ly low tendency to stick with respect to most materials.
This combination en-sures to the user a signi-ficantly longer service life
of his tools and permits extremely high processing speeds. Cutting edges which are as smooth as possible reduce the cut-ting forces and result in less deformation of the material – an important advantage offered by CCDia®TopSharp.
Already visually it appears much smoo-ther, and with the aid of a process pa-tented by GFD, cutting-edge rounding is minimised. Here also the surface is additionally smoothed during the shar-pening process. With these blades it is immediately appa-rent: instead of the black and grey surface seen in the past, the new mirror coating shines. This hard and smooth surface made of 100 % diamond material, i.e. without binder matrix, reduces once again the sticking tendency.
Left: unsharpened, right: sharpened blade.
Service life comparision
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Your contact at CemeCon
Inka HarrandProduct Manager
Cutting InsertsTel.:
+49 (0) 24 05 / 44 70 105
Thosten Rübben, Mohamed Boubrik, Aydin YildirimTel.: +49 (0) 2405 4470 113; -513; -543
Mirror smooth and ultra sharp
CCDia® is a nano-crystalline diamond coating which is used in connection with high(est) precision machining of aluminium, wood, AlSi and TiAl alloys as well as plastic composite materials. It is suited for all planar geometries and consists to 100 % of diamond, i.e. no binder matrix is used. Through the sharpening process, edge rounding is less than 1 µm, thus extremely sharp edges are produced.
The company GFD, Gesellschaft für Diamantprodukte mbH from Ulm, Germany develops and manufactures diamond based products. Moreover, it belongs to the worldwide leading vendors of diamond microtechnology. The products from this company, like diamond coated carbide metal blades with plasma sharpened cutting edges and diamond microcomponents made of pure diamond, are used in the areas of medicinal technology, pharmaceuticals, materials processing and semiconductor technology.
GFD Gesellschaft für Diamantprodukte mbHDr. Andre Floeter, Managing DirectorLise-Meitner-Str. 1389081 Ulm, GermanyTel.: +49 (0)731 / 50 97 759Fax: +49 (0)731 / 50 97 [email protected]
Nach dem Schärfen
Vor dem Schärfen
Sensational service life increase
Dr. Andre Flöter: “Our new Diamaze®-PSD blades are currently attaining sensa-tional increases in service life of appro-ximately 1.500 % compared to ceramic blades when cutting plastic foil materials with pigment inclusions of titanium oxide, and up to approximately 2.000 % compa-red to carbide blades. Moreover, owing to the sharper blades, a smoother cut is attained thereby significantly reducing
the amount of rejects besides attaining a higher processing quality.
Also in the case of machining tools for processing non-iron materials there are some applications in which CCDia®TopSharp can be used with ex-cellent results. Especially in the area of precision ma-chining, frequently very sharp cutting edges are needed since the formation of burrs at the component is a clear failure criterion. Using TopSharp, this can be avoided. n
Left: not shar-pened carbi-de blade; right: CCDia®TopSharp coated blade with sharpened cutting- edge.
Carbide blade Diamond coating
Carbide blade without diamond coating
Carbide blade with diamond coating
Carbide blade with sharpened cutting-edge
After sharpening
Before sharpening
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Without sticking out of the mould!
Amtec GmbH: CCMold Solution for customised tools
Wear, deposits or poor mould removal characteristics – these are provocative words the manufacturers of the processing plastics material industry don’t like to hear at all. But this is not necessary. Modern high-performance coatings on moulds and moving machinery parts do away with these negative characteristics. Amtec, a worldwide leading manufac-turer of precision injection moulding tools is here relying on the expertise of the coating specialists at CemeCon. Through the “CCMold Solution”, CemeCon is making available a complete package of coating solutions which is adapted individually to the respective requirements.
Increasing requirements regarding pro-duct quality or new types of filled, respec-tively reinforced plastic require extreme processing conditions as well as precision injection casting tools. Moulds, ejectors, pins etc. are subjected to increasing wear, higher temperatures or more rapid for-mation of deposits. As a result of this, the tendency to sticking, respectively poor mould removal characteristics, increases. Without high-performance coatings which, depending on the type
of application lubricate and/or protect, reliable manufacturing is no longer eco-nomically viable.
Tool and coating expertise closely interweaved
The company Amtec GmbH from the town of Hohenwestedt, Germany deli-vers its precision injection moulding tools to well-known companies of the plastics processing industry worldwide. Managing
Director Bernd Haefke: “When profes-sionals work together, synergistic effects result which offer to the end user highly beneficial advantages. Here coatings play a key role. Here we are demanding from our partners the same high quality as we demand from ourselves. It is only in this way that we can offer to our customers the best overall solution. And when it comes to the topic of coatings, we have already been cooperating for many years with CemeCon. Because comprehensi-ve consulting expertise, technological leadership but also the rapid delivery of the coated tools are decisive criteria for us”.
Modern high-performance coatings on moulds and moving machinery parts do away with rapid wear, deposits or poor mould removing characteris-tics.
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Christen A. Straede, Managing Director of CemeCon Scandi-navia: “Our CCMold Solution, a complete package of coating solutions for mould manufacturing is the fast seller for mould and tool manufactur-ers in Scandinavia and Northern Germany. Our innovative low temperature techno-logy for smooth, im-maculate surfaces and a broad line of coatings as well as accompanying support are unbeatable”.
Bernd Haefke: “Amtec offers also so-called turnkey solutions. These com-prise of complete injection moulding production lines, where already at the planning stage the coating specialists, among others, are involved so as to de-velop right from the start the optimum system configuration for our customers like, for example the “ Amtec 4” injection
CCMold Solution
CCMold Solution is a complete solu-tion package for mould and tool ma-kers. Once the tool design has been completed, the right coating for the application is defined. It shall facilitate separation of the injection moulded part from the mould. In certain cases it must also offer lubricating properties so as to avoid sticking.For this, the CemeCon portfolio includes among others the pro-ducts CCMold CrN, CCMold DLC, CCMold TINALOX®, CCMold CRO, CCMold NCrN as well as for metal re-forming CCForm TINALOX® SN², CCForm CrN and CCForm TICANOX®.
The company Amtec GmbH, Advanced Mould Technologies, is the German subsidiary of Went-worth Technologies Inc., one of the largest tool and mould manufacturers worldwide with production
sites in Canada, USA, Poland and in the German town of Hohenwestedt with a workforce of 90. Amtec belongs to the worldwide leading tool makers of precision injection moul-ding tools for the plastics processing industry.
With over 45 years of experience in the manufacture of precision tools, the com-pany founded in 1956 supplies its products to worldwide renowned companies active in the area of medicine technology, electronics, electrical engineering, auto-motive industry and the toys industry, telecommunication as well as the consumer goods industry – with a full-service from development to the finished product.
Contact:
Amtec GmbHManaging Director Bernd Haefke,Project Manager Frank Hamann Vaasbüttel 16-2224594 HohenwestedtGermanyTel.: +49 (0) 48 71 / 37 -0Fax: +49 (0) 48 71 / 37 -21 [email protected] [email protected]
Your contact at CemeCon Scandinavia
Ph. D. Christen A. Straede
Managing DirectorCemeCon Scandinavia
Tel.:+45 70 22 / 11 61
Through the latest h.i.p. system CC800®/9 MLT for low-temperatu-re coatings, high-tech for coating of moulds is available. Coating tempe-ratures of around 180° C and below help to protect even most heat-sen-sitive substrates.
The new h.i.p. technology opens up the way to an entirely new quality level – surface qualities and coating qualities that previously were not possible at such low temperatures: smooth, impeccable surfaces and increased reliability.
moulding solution, which a short while ago was shipped to Africa. In the case of machines which need to be productive under more extreme ambient conditions, the coatings need to provide optimum characteristics, among other things. For this reason, all moving parts like the ejector, pushing components or guide strips were coated with the lubricant coating CCMold DLC and the cavities with CCMold CrN so that nothing may seize – not even in Africa!”
Managing Director Bernd Haefke has found the right CCMold Solution.
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CC800®/9 JET: compact design, full performance
Top-quality and economy also at low tool throughputsThe CC800® family of coating systems has grown: through the youngest and smallest addition, the CC800®/9 JET, CemeCon is completing its offerings of smaller systems thereby permitting also small to medium-sized vendors to economically enter into the area of in-house coating. And when the capacity needs to be expanded, the coating system simply grows by demand.
In-house coating offers numerous benefits: what otherwise is done ex-ternally, is now run door-to-door with one’s own production facility. In this way work processes can be optimised and the response times with respect to market requirements can be drastically reduced. Moreover, through one’s own coating system CC800®/9 JET, the entire coating competence is at the fingertip, so to speak. This offers to the manufacturer the possibility of creating his own unique products thereby decisively setting him apart from the competitors. He himself defines and designs his entire product himself – because only through first-class
coating qualities is it today at all pos-sible to manufacture com-
petitive tools at the highest level.
Entry made simple
To anyone putting his money on Cem-eCon technology around the CC800®/9 JET coating system, CemeCon presents a cost-effective solution which is al-ready economic at low tool through-puts. Through this system a complete production line can be integrated within one’s own company: coating, cleaning, blasting and preparation techniques, cooling as well as batching materials and handling systems are all included. Such a production facility is very easy to plan and commission. For this, CemeCon has committed and experienced staff, who will at all times assist the customer from the first drafts through installation and commissioning up to production start-up. Moreover, all systems from CC800® family are, by design, easy and conveniently to operate.
The new CC800®/9 JET is the ideal entry-level coating system and is par-ticularly well-suited for lower coating throughputs. Already at low through-puts, the JET is, just like all other systems of the CC800®/9 line, already extremely economic. It offers the high-est quality since it already integrates the latest engineering developments. That CemeCon is on the right track is demonstrated by numerous success-fully installed systems and the positive remarks received from satisfied Cem-eCon partners.
Increased performance on all levels
Is such a “downsized” system at all in a position to deliver full performance? Already through the entry-level system CC800®/9 JET the tool manufacturer has
made a decision regarding the entire performance scope of the “large CC800® brothers”: the small, modular coating system delivers precisely the same extremely smooth, highly adhesive and drop-
let-free sputtered coatings as they are typical for CemeCon.
Machining hardest materials – during processing, tools coated with super-nitrides last significantly longer: hob cutters will no longer lose any teeth so quickly, drills and milling cutters will
have to be replaced only after longer in-tervals.
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Your contact at CemeCon
Dr. Peter BallhauseProduct Manager
Technology TransferTel.:
+49 (0) 24 05 / 44 70 110
[email protected] a small turnkey solution offers the highest coating quality.
The new star of the coating family: through the small modular CC800®/9 JET, CemeCon is com-
pleting its offerings on the entry-level market, there-by offering to small and medium-sized vendors a cost-effec-
tive entry in to in-house coating operations.
And these ensure the decisive lead over the competition: already when selecting and combining the coating materials, al-most all options are open thanks to the sputtering technology used. On one and the same system it is possible to pro-duce all possible coating materials like SuperTiN, TINALOX®, HYPERLOX®, HSN² and super nitrides.
Through these high-performance coat-ings, previously unheard of applications can become reality. They excel, among other things, through an extreme degree of wear resistance, improved oxidation resistance as well as high hardness and
warm hardness. Through the immacu-late surfaces of the low friction coatings, significant increases in performance can be attained in connection with all ma-chining operations: thus it is, possible to operate the tools at higher cutting speeds, and also a rapid chip removal is ensured during drilling operations, for example. Here the coating is almost free of residual stresses and adhere perfectly on the respective substrates and geometries.
Such excellent properties result in an increased productivity through a significantly longer tool service life,
respectively shorter down-times while at the same time offering an improved machining characteristic and an optimum surface quality – an edge over the competition, through which the market can be impressed.
Highest quality standards
Already the basic JET sys-tems are capable of coating up to 900 drills, respectively 2,450 indexable inserts within the shortest period
of time. Throughputs, with which many vendors can produce economically for quite a while. And when coating com-plexity increases, then CemeCon has the matching solutions. All CemeCon coating systems are based on the same system design (CC800®/9) and identi-cal process engineering. In this man-ner CemeCon attains, using the JET system, the production of the same coatings of the same high quality as for the “large systems” whereby the aspect of economy remains the same – a significant benefit especially should the user want to change later on to a dif-ferent CemeCon system. He may simply transfers his well proven coatings to the new system without having to change production. And in doing so, the menu guided user interface of the systems will always remain as simple as can be. n
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For a total of two years, the tool manuf-acturer Seco Tools which manufactures the Seco-Jabro carbide milling cutters, has worked on a programme to increase stability during the manufacture of mono-lithic aluminium components used in the aircraft industry. Such aluminium parts are used in the cockpit and in the transitional area between body and wings. In order to increase process stability as well as in-crease service life and thus productivity, the company closely cooperated with the manufacturing department of Airbus Méaulte.
Precise measurements on tools and materials
The jointly developed tools were used in the production unit of Airbus Méaulte, and microchips in the tool
holder collected data as to tool service life during milling operations. There-after the condition of the tools was analysed in the test centre at Lottum (The Netherlands) by measuring the forces occurring during milling opera-tions using the original Airbus material. Also the machined material was inves-tigated so as to obtain information on its structure after a defined period of tool usage.
After the first tests it was apparent that the aluminium sticking effect was the reason for the higher forces during the milling process. These in-fluence the structure of the material to be machined and thus also service life in a negative way. In close coope-ration between Airbus and Seco Tools the future requirements were defined. Doubling of tool service life so as to
increase productivity, but also to attain a stable manufacturing process at the Méaulte factory.
Optimised coating for best results
CemeCon developed for the Seco-Jabro carbide products of Seco Tools the cus-tomised Mega-T coating, a solution op-timised in view of the stringent require-ments at Airbus. Also the pre-treatment of the tools was scrutinised by the engi-neers and they developed a special pro-cess significantly reducing the aluminium sticking effect. Also handling of the tools within the Airbus factory was improved so as to attain the utmost precision during the manufacturing process.
“The combination of all these factors allo-wed us finally to attain the challenging tar-
Photo: Airbus S.A.S.
Lift off easier
Airbus, Seco Tools with Seco-Jabro tools and CemeCon
Aircraft manufacture and light weight construction are commonly mentioned together: and rightly so because without advanced designs and materials modern jets could no lon-ger fly their passengers economically anymore. So that the high-tech materials used can also be processed with cost efficiency in mind, special tools are required – customised to the area of application and with a service life which is as long as possible.
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Light weight construction experts among themselves (from the left): Oliver Lemmer (CemeCon), Marcel Aarts (Seco- Jabro), Jean-Claude Mirey (Air-bus Méaulte), Jean-Paul Davoine und Philippe Limousin und Patrice Camer-lynck (all from Seco Tools France), Claude Berthomier (Airbus Méaulte) and Manfred Weigand (CemeCon).
get and brought about the decisive progress in productivity for Airbus” says Ing. Marcel Aarts, Head of the Department of Research and De-velopment at Lottum, where the Seco-Jabro carbide tools are being manufactured
Ing. Marcel Aarts: “We have scru-tinised the entire process from substrate and geometry through grinding and pre-treatment up to coating.
Here are all parameters had to be matched perfectly with respect to each other. Only through the excellent co-opera-tion of all involved at CemeCon and Seco Tools were we able to reach the challenging target we had set ourselves so as to opti-mise production at Airbus to the satisfaction of all.”
Seco Tools, where the Seco-Jabro carbide tools are being manufactured, based in Lottum, The Netherlands, is a modern company manufacturing high-quality carbide milling tools for the machining industry. For customers worldwide the company is developing innovative machining concepts and the corresponding tools. Here the company already certified in 1994 according to ISO 9001 and since 2006 also according to ISO 140001, attaches great importance to utmost quality and full customer satisfaction. This is attained among, other things, through customer teams composed of sales, application as well as production engineers who thus can optimally respond to customers requirements. Moreover, the company is offering a re-grinding service with full process reliability.
Contact:
Seco-JabroLeader Research & DevelopmentIng. Marcel AartsZamdterweg 145973 RC LottumNetherlandsTel.: +31 (0) 77 / 46 32 444Fax: +31 (0) 77 / 35 80 588 [email protected]
Your contact at CemeCon
Dr.-Ing. Beate Hüttermann
Executive DirectorSales Europe
Tel.: +49 (0) 24 05 / 44 70 110
At the Airbus production fa-cility, utmost precision and state-of-the-art tools are an absolute requirement.
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Regional sales
Always at the customer’s “pulse”
Already upon purchasing a CemeCon coating system CC800® or a coating solution, the customer receives the good service he is accustomed to at the same time. Which coating material is suited for which application, are there engineering questions? In such cases they are much in demand: because each region has its own ex-perienced customer advisor directly at the customer’s location. And behind the scenes, moreover, a competent support team is ready to support the customer in all aspects.
Directly available to the customer, the following staff is at hand at any time to respond to questions of the customer.
The tasks of Jörg Schnitzler at Ceme-Con are numerous. Besides managing the department Sales Support he is re-sponsible for organisation and handling of the operative daily business thereby providing support for the customers and
the field service. Privately he likes a good workout. In winter through snowboar-ding, in summer through in-line skating and jogging – and when it happens to rain he likes to potter around in the house.
If Silvia Busch is not to be found in the theatre, you can find her with her came-ra taking instant pictures. The expert for the area of spare parts and targets in the systems business at CemeCon likes
sports providing her with the strength for tackling new tasks, and she often puts on the running shoes.
Gabriele Diehm is also responsible for the spare parts and targets business, and in her spare time likes to go jogging and swimming.delete the
A smile on her face, this is typical for Petra Schoof when welcoming custo-mers on the phone or at the reception desk. She likes to relax during long walks with her dog. Sometimes even far away. Because at CemeCon she organises the business trips of her colleagues and priva-tely she also likes to go on tour herself.
Order processing of engineering and test reports as well as internal project and order coordination are the areas where Christian Klein excels. Is organising talent comes handy also privately when travelling with his family. When he wants to relax after work he grabs his bicycle for a round.
The Sales Support Team provides useful tips and information around the CemeCon products (from the left: Christian Klein, Aydin Yildirim, Michaela Pütz, Silvia Busch, Yuan Werner-Guo, Petra Schoof, Mohamed Boubrik, Jörg Schnitzler, Gabriele Diehm and Thorsten Rübben.
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Customer service, order pro-cessing and control as well as the preparation of offers in the coating service is the domain of Thorsten Rübben, Aydin Yildirim, Michaela Pütz and Mohamed Boubrik. Moreover, Thorsten Rübben is in charge for engineering consulting and for supporting the area of enginee-ring. Privately Thorsten Rübben likes to ride his motorcycle, pot-ter around or travel to foreign countries. Mohamed Boubrik likes to go jogging in his spare time, likes to read or play soc-cer. Drawing and fitness training are the great passions of Aydin Yildirim. Michalea Pütz, an Industrial Business Management Assistant, likes to go to the cine-ma and visit concerts. She likes to listen to music a lot and is highly enthusiastic about the USA, a country which she has already visited many times.
Yuan Werner-Guo is at Ce-meCon in charge of supporting the Chinese market. The born Chinese speaks fluently Ger-man, Chinese and English, and has been living in Germany for six years now. Privately she likes to walk around together with her family enjoying nature. Her hob-bies are in-line skating, dancing and gymnastics.
Regional sales: Quickly on location
Helmut Schauenberg who provided very substantial support in connection with building the CemeCon Service and Logistics Centre in Brunswick, Germany, takes care of the “northern inhabitants” of the country. While ensuring at the cus-tomers smoothly running processes, he is privately more interested in long-distance running, swimming and diving as well as the cooking abilities of his wife.
Thomas Schaaff provides his many ye-ars of experience in the area of coating technologies to his customers in German postcode areas 5 and 6 as well as in Aus-tria. Our man for the South West is a great soccer fan and during international soccer matches and international tour-
The staff of CemeCon Regional Sales is available on locations throughout Germany quickly and without any hassle.
Helmut SchauenbergTel.: +49 (0) 170 63 10 744
Metin CetinTel.: +49 (0) 171 9700 737
Thomas SchaaffTel.: +49 (0) 2405 4470125
Marc SemderTel.: +49 (0) 171 9700 736
Frank SchönbernerTel.: +49 (0) 170 6310 718
Matthias UnserTel.: +49 (0) 170 6310 711
naments he is “at home” in all stadiums of the world.
Metin Cetin is available to CemeCon customers in Franconia, Saxony and Thuringia. Since moving together with his family to Saxony, he also likes this area privately very much. Although he currently lacks the time he is, as in the past, still a sports enthusiastic. He relaxes during long walks with his dog and family.
Where do motorcar enthusiasts like to live? Of course in the vicinity of the ma-
jor car manufacturers and their suppliers: Marc Semder is in charge of CemeCon Sales in Stuttgart, Swabia, and Allgaeu. He has lost his heart particularly to old-timers of the 50s to 70s.
Matthias Unser is also on the road in German postcode area 7 but also down to the Swiss border. He is a skilled tech-nician specialising in the area of process engineering. Matthias is married, has se-ven-year-old daughter and a Jack Russell
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Support in the background
The product management team at CemeCon provides engineering support for the sales department. The team is composed of three experienced people from the branch:
Hob cutters and shaft tools are the professional areas where Manfred Weigand feels at home: during his time with the field service he gained a lot of important experience and due to his know-how he is the right person to speak to. Most of his spare time is reserved for his youngest offspring.
Inka Harrand is the competent contact person when it comes to indexable inserts. Many may still know her when she was with Sales.
Dr. Peter Ballhause likes music: whereas in the past he himself played in a band, he now, in his spare time, likes to listen to a CD or attend to his dog. Actively he is utilising his know-how gained over 17 years in the area of PVD and CVD coating technology in the development of the systems at CemeCon.
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Terrier who most of the time responds to the name of “Milo”. In his spare time he li-kes to ride his mountain bike, accompany his daughter to tournaments and likes to jog. Currently he is putting a lot of work in to restoring his 1962 Kreidler Florett motorcycle.
Through his infectiously good humour, the skilled machining mechanic Frank Schönberner does not only convince his colleagues but also in particular his customers in Bavaria. True to the spirit of a glowing technology fan he tinkers a lot on old TV sets, but he also knows how to relax during running or badminton as well as reading and cooking.
Darren Cox lives in Dorset on the South Coast of England together with his part-ner Julie, two daughters and his four-year-old son. The CNC programmer and ope-rator is in charge of Sales in England. For 17 years Darren has worked in the job he initially learned but then changed to Sales – since October 2006 at CemeCon. He likes to spend most of his spare time with his family and go angling.
Donation for “Zappelphilipp“:
Social commitment is also important at CemeCon
That social commitment can give rise to joy in several ways at the same time is demonstrated by the annual Christmas party of CemeCon at Würselen, Ger-
Tradition with an added value: already nine times CemeCon has supported from the reve-nue of the Christmas party the Sozialdienst katholischer Frauen e.V. Alsdorf (SkF) (Social Service of the Catholic Women) in their project “Zappelphilipp“ (Fidgety Philip).
many. The raffle in favour of a non-profit organisation is entirely organised by the trainees of the company. In 2006, this task was successfully completed by Ka-trin Knipprath our Industrial Business Ma-nagement Assistant trainee, and Sebastian Jung who is being trained by CemeCon to become a mechatronic engineer. Together with the management board members of CemeCon, Toni Leyende-
cker and Oliver Lemmer they announced the first prize during their excellent stage appearance.
The amount of 678 � was, in best tradi-tion, again handed over to the SkF Als-dorf for their „Zappelphilipp“ project. This project which is financed solely by donations actively promotes deprived children.
Here the SkF offers, among other things, family aid, school assistance as well as nu-merous group events. The donation from CemeCon will be used to finance the annu-al holiday trip in summer – something the children will enjoy very much again.
Mrs. Schuppener (left), head of the “Zappelphilipp“ group receives a cheque of 678 � from the CemeCon trainees Kathrin Knipprath and Se-bastian Jung (right). n
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“Heavy duty” Supernitride HYPERLOX®:
Smooth flow of chips
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Your contact at CemeCon
Manfred WeigandProduct Manager
Round ToolsTel.:
+49 (0) 24 05 / 44 70 135
Grey cast iron (GG), cast iron with vermicular graphite (GGV) or cast iron with spheroi-
dal graphite (GJV) are, beside aluminium, important materials used in the manufacture
of high-performance combustion engines. However, the advantages offered by these
materials suffer on the other hand through the extreme requirements in connection
with processing these extremely abrasive materials.
In times where engine performance is increasing ever more but where engines at the same time shall be lighter in weight and petrol saving, optimised materials are much in demand: for example, in the automotive industry high-strength cast iron materials like GGV and GJV have established themselves, capable of eas-ily managing the stringent requirements in connection with brake discs or direct injection diesel engines or turbocharged petrol engines. At the same time the requirements regarding the tools used are increasing very significantly, since high-tech cast iron is extremely abrasive so that, for example, conventional car-bide drills coated with TiAlN wear out all too quickly.
Reliable process drilling with supernitrides
Modern coating solutions offer tremen-dous production benefits in such cases. Manfred Weigand, Product Manager Round Tools at CemeCon: “Machining of cast iron is a demanding application to which we have adapted our heavy duty supernitride HYPERLOX® specifi-cally for drilling operations. Depending
on customer requirements, the thickness or finish of the coating is precisely matched to the types of drill and drill geometry used. With HYPERLOX® we are able to coat carbide drills ranging from 1 to 32 mm in diameter and of course also those items with a cooling channel”.
The high degree of wear protection for the drills is guaranteed by HYPERLOX® among other things by its composite structure which exhibits an extremely high share of aluminium thereby ensuring hardness. On the other hand the coating material HYPERLOX® is particularly tough. At the same time the coating exhibits extremely low friction levels – remov-ing the chip from pocket holes or through-holes is effected without any problems.
Manfred Weigand: „Regardless of whether the grey cast iron materials GG25, GG27 or GGV need to be machined – through the CemeCon Supernitrides ALOX® SN² or HYPERLOX® the users attain an ex-ceptional level of dimensional accuracy while at the same time maintaining an excellent surface quality. Thus our coatings are providing a new impe-tus regarding economy and process-ing quality”.
HYPERLOX® – Supernitride for „severe cases“Regardless of being used dry or wet – HYPERLOX® is suited for processing materials which are difficult to cut and for hard processing. This high-per-formance coating excels through its freedom from droplets and its smooth surface, fine coating structure, its extreme toughness and very high hardness as well as utmost oxidation resistance and hot hardness. Owing to its extremely good adhesive properties, HYPERLOX® excels in particular when subjected to high shear forces as encountered when processing materials which are difficult to machine and which “smear”.
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In order to successfully open up this in-teresting market it is, however, essential to enter into fruitful cooperations with local companies. CemeCon has found in KBS (Korea Business Services Ltd.) a particularly competent and reliable partner. For quite a few years now KBS has been representing companies from foreign countries, German companies in particular, as a representative for the Korean market. This company manages to provide the link between the German and Korean culture thereby representing to interested parties from Korea the op-timum contact partner:
Without language barriers, specific pro-blems can be solved more rapidly and also the geographic proximity helps to provide the best possible assistance to Korean customers at any time. Moreover, the experts at KBS have at their disposal a comprehensive engineering know-how as well as an accurate knowledge of the market rules and legal aspects which apply in their country.
Hand-in-hand forsatisfied customers
In the rapidly growing Korean market there is already a great interest in Ce-meCon coatings. With the aid of the KBS this interest can now be served by being present in the country itself. Beyond this, customers in Korea already working with
With about 80,000 visitors and over 400 exhibitors from 25 countries the Korean tool machine exhibition Simtos 2006 was again able to note excellent results. Also this time CemeCon was represented at a booth. And this for good reason, because Korea which in the meantime has advanced to 10th place of the worldwide greatest industrial nations, has become an interesting market for foreign investors.
Contact:Korean Business Services Ltd.Mr. Hong-Sik Cho (Representative Director)401 Shinsung Miso City, 96-3, Hannam-dong,Youngsan-gu Seoul, South Korea (Postcode: 140-210)Tel.: +82-2-792-2430 Fax.: +82-2-796-2419www.infoskorea.com
Morning call in the countryof morning quietness
KBS: Korean market in good hands
CemeCon technology will of course be served also in future by the CemeCon customer service. n
A clearly laid out homepage is important to present one’s own products as best pos-sible. For this reason CemeCon is presenting itself beginning in the first quarter of 2007 through its new Internet presentation. The three divi-sions System Engineering, Coatings and Applications can already be found on the homepage allowing the CemeCon offerings to be accessed directly. Thus the company demonstrates that it is not only state-of-the-art in the area of coating technology but that it is also capable of meeting the requirements regarding design and user-friendliness.
Internet presentation refreshed
Imprint
Editor:KSKOMM • Pleurtuitstr. 8 56235 Ransbach-Baumbach, GermanyTel.:+49 (0) 26 23 / 900 780 Fax:+49 (0) 26 23 / 900 778www.kskomm.de • [email protected]
All rights reserved. Reprints, even extracts only with permission of CemeCon.
Published by:CemeCon AGAdenauerstr. 20 A452146 Würselen, GermanyTel.:+49 (0) 24 05 / 44 70 100 Fax:+49 (0) 24 05 / 44 70 [email protected]
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