PERFORmANCE NEWS

Performance
News
LMT Tools Magazine 2013 / 2014
Gear Runner INternal
WORLD FIRST:
HOBS FOR INTERNAL
GEAR CUTTING
ROLLING SYSTEMS: MAXIMUM QUALITY FOR THREAD Production
GLOBAL PRODUCTION: NEW PLANT OPENED IN INDIA
1
3 Editorial
5 TOOL INNOVATIONS
LMT auf der EMO Hannover
16. – 21. 09. 2013
Halle 4, Stand E54
4 Shaping Processes
efficiently
Interview with Jochen Eichert,
Managing Director at LMT Tool Systems
5
8
TOOL INNOVATIONS
High technology
Indexable insert gear hobs for
internal gear cutting
10 Chip Overflow
Hobbing with the SpeedCore at
Claas Industrietechnik
12 EXCELLENT CONNECTIONS
Rolling API threads
14 Top Class
Nanomold Red triples the service life of tools
in die and mould making
16 SPIRIT OF OPTIMISM
Production facility opened in India
16 LIGHTWEIGHT AND STABLE Machining honeycomb boards for
lightweight construction
18 TOOL MANAGEMENT
The key to efficient tool logistics
8 high technology
Discover efficiency
spitzenleistung fÜr
iHre proDuKtion
Spitzenleistung heißt, nur das zu machen,
was man besser kann als andere. Als Werkzeughersteller konzentrieren wir uns deshalb auf Verfahren, für die wir technisch
überlegene Lösungen bieten. Besuchen Sie
uns auf der EMO 2013 und entdecken Sie,
wie Sie mit unseren Werkzeugen die Effizienz
Ihrer Produktion messbar steigern können.
Unsere Messehighlights:
– Machining on Demand: Mehr als
20 Werkzeuge im Praxiseinsatz
– Innovationen: 10 neu entwickelte Werkzeugsysteme und Beschichtungen
– Erfahrungsaustausch:
Die Werkzeug spezialisten der
LMT Tools beraten Sie gerne
Wo wollen Sie effizienter werden?
Sprechen Sie mit unseren Experten.
www.lmt-tools.com
14 PREMIER LEAGUE
18 service international
On location for LMT customers
PUBLICATION DETAILS
Design: Braun Engels Gestaltung, Ulm
Publisher: LMT GmbH & Co. KG
Print: AW-Offsetdruck e.K., Freigericht
Heidenheimer Str. 84, D-73447 Oberkochen, Germany
Tel.: +49 7364 9579-0
© LMT Tools GmbH & Co. KG, 2013
E-mail: [email protected]
All rights reserved. Subject to errors in content and printing.
Responsible in terms of press law: Christian Pott,
Reproduction only with permission of the publisher.
LMT GmbH & Co. KG
Editor in Chief: Christian Pott, LMT GmbH & Co. KG
Images:
Concept and editorial: Script Corporate + Public
All image rights are clarified.
Communication GmbH, Frankfurt am Main
2
Dear
Readers,
“Discover Efficiency” – the cover theme of this
Compromise is not part of the equation. Only if a
edition of Performance News is itself an invitation.
solution excels in every efficiency-criterion will we
We would like to encourage you to discover the reser-
offer it to you. Efficiency means doing the right thing –
ves of efficiency that lie hidden in your manufacturing
this is a philosophy which guides our work for you.
processes, and which you can tap into using our tool
solutions.
The projects which we will be presenting to you in
this magazine show just how much influence precision
But what do we actually mean when we say efficiency?
tools can have on the efficiency of production proces-
For us, efficiency is more than just a number. To us,
ses. I would like to invite you to be part of this success-
efficiency – both yours and ours – is a goal towards
story. Our experts look forward to helping you to
which to strive. That goal requires tools with which you
solve complex requirements and to providing you
can make your production faster, more precise, safer,
with genuine partnership on site. I hope that reading
more flexible, and cheaper. But that is just the begin-
Performance News provides you with ample inspiration.
ning. A system is not really efficient until we have
looked at the entire process together with you, and
Regards,
identified solutions that guarantee you competitive
Matthias Rommel
advantages long-term. These will include intensive
Managing Director and Spokesman for LMT Tools
on-site support, by specially trained application technicians, as well as comprehensive services.
Suggestions or queries?
Write to: [email protected]
Discover our new website: www.lmt-tools.com
3
with some of the world’s most far-reaching tool management
projects. Currently we are the tool manager assisting a gear
manufacturer in what is to date its largest ever investment project
in the US. We have been successful in China for the past ten years,
achieving results that can be measured. This is why we will be
building up our international range of services and direct sales
from now on.
What new developments c an users expect soon
from LMT Tools?
Jochen Eichert
Managing Director of LMT Tool Systems
SHAPING
PROCESSES
EFFICIENTLY
We remain true to our aspiration to develop new, more powerful
tools each and every year in our areas of core competence. But we
do not limit ourselves to tools alone when it comes to innovation;
we also evolve the services we offer. From next year onwards, we
will for example be offering our customers life-cycle contracts for
special products in the field of gear cutting. This means that
customers will be paying for a sharp cutting edge, not just for the
tool itself.
Precision tools are the key to efficiency in industrial
manufacturing. But what does that mean in real terms?
The experts at LMT Tools consider the entire process in
every project – from the machining strategy all the way
to the choice of suitable tools. This allows them to
Mr. Eichert, what themes are LMT Tools customers
deliver solutions which measurably increase users’
currently focusing on?
performance.
As always, what concerns our customers most is to become that
little bit better each and every day. The perspective, however, has
changed somewhat. Instead of concentrating on details alone, our
customers are looking more and more at their production as an
overall process. International collaboration is also playing an
increasingly important role. To us this means that we have become responsible not only for our tools and the quality with
which they are made, but also for stable production processes in
general – and this to the extent that we have to allow our performance to be measured in terms of fixed unit costs.
Longer service life
Pioneering coatings on surfaces, such as Nanomold Red,
help tools last longer and machines to work on undisturbed.
Higher output
Greater production figures can be achieved in the same
production time – by using, for instance, stronger materials
and faster milling times.
Improved quality
How c an you influence that?
Top quality production demands top tools that fulfill the
Don’t underestimate a tool manufacturer! As a globally active
enterprise, LMT Tools has gathered together an enormous
amount of knowledge about processes and procedures over recent
years. We combine this knowledge with our technical expertise
in order to establish ourselves as a competent partner in our
customers’ process planning. What we focus on are the areas of
application in which we supply superior solutions. The competitive
advantage which this gives to our customers is obvious. We assist,
often on site, in making processes more efficient and in reducing
production costs.
narrowest tolerances and minimize material wastage.
Lower costs
One example of how innovation can reduce cost is a
high-grade tool that can be used for more than one working
process – without loss of quality.
High level process security
LMT service is on-site service – globally. Indeed, that is the
only way to ensure that a solution is tailored precisely to a
customer’s manufacturing process.
Can you give us an example?
Take the area of tool management. Based on our expertise in the
field of gear cutting, we have, together with our partners, dealt
4
The new universal cutter from LMT Fette.
Three specialized cutting materials
guarantee ultimate performance when
milling steel, stainless steel, gray cast
iron, and titanium:
• Eight usable cutting edges per
indexable insert
• Positive cutting edge geometry
for resource-saving cut
• Available diameters 40 to 125 mm
MULTIEDGE DOUBLE 8
Complete range of milling holders and
indexable inserts for machining steel and
cast iron:
• Holder body diameter range between
32 and 200 mm
• 16 usable cutting edges per indexable insert
• New wiper blade geometry
DHC INOX PREMIUM
End mill family with unequal spiral angles
(DHC = Different Helix Cutter) for machining stainless steel:
• 300 percent higher chip removal rate
• Very smooth-running
• Multifunctional: roughing, finishing, slot cutting, ramping, and drilling – with a
single tool
TOOL INNOVATIONS
MULTIEDGE 45 DOUBLE4
UNIVEX PREMIUM 90°
Shell end mills with high-positive cutting
edge geometry and unequally divided
cutting edges for roughing:
• Cutting depths of up to 16.5 mm
• Available as end and slot-on mills
• Broad range of indexable inserts with different corner radii
NANOSPHERE 2.0
The latest generation of the world’s first
nanostructured coating for hobs:
• Up to 40 percent longer service life
• Suitable for all substrates: HSS-PM, SpeedCore, and carbide
• Refurbishment in manufacturer’s quality within the international LMT Tools network
NANOMOLD RED
The world’s first coating for finishing
cold and hot forming tool steel, cast
steel, and hardened materials up to
65 HRC in mould and die construction:
• High impact resistance
• Suitable for dry machining
• Reddish outer layer for easy
application identification
6
Perfect cutting results with more teeth in
all diameters:
• Shorter production times
• Absolute process reliability
• Ultimate surface quality
MULTIEDGE TAN 90 DOUBLE4
The new milling system for ultimate
performance in machining cast metal:
TOOL INNOVATIONS
FINISHLINE PREMIUM
• High stability on account of tangentially arranged indexable inserts
• Eight usable cutting edges per
indexable insert
• Special chip breaker geometry for cast
iron machining
MICRO HSC LINE
Complete range of solid carbide tools with
spherical, toric, and straight front geometries in a range of cutting edge lengths for
micromilling:
• Complete range with diameters from
0.2 to 3 mm and a range of cutting edge lengths
• Application-specific cutting edge
preparation
• Innovative coatings
high
technolog y
Indexable insert gear hobs for
internal gear cutting
You can’t see them, but they play a
major role in modern wind turbines.
When you have to lift 50,000 kilograms to a height of almost 100
meters above a construction site,
and when the 350 ton nacelle in a
wind power plant rotates in the wind
of a storm, then it is the high-precision gear rings inside that enable
such movements to take place at all.
The better the pitch accuracy, the
smaller the oscillation at the end of
a large-scale system, and the higher
the efficiency of a wind turbine –
these are just examples. That is how
gear cutting tools directly influence
the performance and safety of
systems.
8
Ring mounts in large-scale gearboxes demand highest
quality standards. By developing a completely new tool,
LMT Fette has for the first time enabled internal gear
cutting on rings of 800 millimeters and above in a continuous hobbing process.
LMT Fette has named the new hobbing system the Gear Runner
Internal, having developed it together with machine-builder
Liebherr-Verzahntechnik. The results are impressive. This
internal hob allows users to achieve gear quality up to Level 6 on
existing machinery without any subsequent processing. All you
need aside from the new tool is to adjust your machine software.
Gear Runner Internal 2.0
A tradional process
made new
A world first – rediscovered
To users this may sound simple, but to developers it has been a
considerable challenge. “When you are hobbing external gears,
the tool is structured evenly, and different numbers of teeth can
be produced, but for internal gear cutting the tool has to be
adapted to the curve of the gear ring. What this means is that
every single cutting edge on the internal hobber is shaped
differently,” explains Thomas Falk, who directs the Gear Cutting
segment at LMT Tools. “We used our design software to analyze
the complex processes involved. In a simulation we were able to
calculate the tool in such as way that only five different indexable
inserts were required to produce the necessary profile.”
Gear Runner
Complete solutions for hobbing
large-scale gears
From now on, LMT Fette will be marketing its indexable
insert gear hobs under the name Gear Runner. This encompasses the well-known modular external gear cutting range
(Gear Runner External), as well as the internal hobbers
launched in September 2013 (Gear Runner Internal). For
cutting materials we are using both the well-established
LCP 35H, and the LC 630 Xt with Nanotherm, the world’s
first thick layer used for large-scale gear cutting.
The performance of modern software plays a major role in new
developments. One person who understands this better than most
is Oliver Winkel. “Internal hobbing is in principle an tradional
process,” explains the Director of Technological Development and
Application Engineering – Gear Cutting – at Liebherr-Verzahntechnik. “It disappeared in the early 1970s, partly because the
machines back then were not rigid enough to produce large-scale
gearing at a high enough quality. Apart from that, the expense of
building the tools was too great.” That has now changed. In just
one and a half years, engineers at LMT Fette developed this new
tool, which is now ready for market. The Gear Runner Internals
have been enduring a tough test at Liebherr since August 2013. It
was above all the quality of the gears that convinced Liebherr, a
corporation which itself is one of the world’s leading manufacturers and users of ring gears and large-scale roller bearings. “The
gears we produce using the Gear Runner Internal demonstrate a
much higher divisional accuracy than those produced conventionally. The quality of the surface finish is also better.” Altogether,
ideal qualifications if you are a top player in large-scale gear
manufacturing.
Producing
an internal
gear ring
using the
Gear Runner
Internal at
LiebherrVerzahntechnik
For more information about LIEBHERR: www.liebherr.com
9
Chip Overflow
Hobbing with the SpeedCore at Claas Industrietechnik
Modern agricultural machinery is driven by engines that
produce hundreds of horsepower. The drive systems used in
tractors, combines, and forage harvesters have to translate
enormous amounts of torque. Claas Industrietechnik (CIT),
a subsidiary of the CLAAS Group, designs and manufactures
axles, running gear, and transmission systems that can cope
with such loads. The company expects nothing but top
performance when it comes to production. A year ago they
converted some of their gear production facilities in Paderborn to the new SpeedCore hobs from LMT Tools.
THREE QUESTIONS FOR …
Thomas Falk
Director of the Gear Cutting segment at
LMT Tools
What, in a sentence, can
SpeedCore do?
With SpeedCore, users can make
high-volume production of gears
much more efficient; productivity
rises by at least 30 percent.
10
“We did have a problem,” recalls Ralf Schneider as he thinks back to
the switchover to SpeedCore, laughing: “The chip containers at the
hobbing machines filled up too quickly and we had to keep on
emptying them.” Apart from that, the new generation of hobs from
LMT Fette fulfilled every expectation. Schneider is the master
technician responsible for process optimization at CIT’s gear
production in Paderborn. Changes to tools and processes are at the
heart of his work. “Gear production has changed a lot over recent
years. The installation space available for gearboxes has become
smaller, while the power that has to pass through gearboxes keeps
How is that possible?
It is a result of the intermetallic cutting material of the hob,
and its high-performance coating. The cutting material is
much harder at heat than tools made from high-speed steel
manufactured using powder metallurgy. This means that users
can take full advantage of the power reserves of their hobbing
machines, and increase their cutting speeds significantly.
Is this tool already used on a large scale in
industry?
Absolutely. SpeedCore is currently used by big-name vehicle
manufacturers and large-scale supplier who have converted
many areas of their gear production. SpeedCore has already
become an industry standard.
on rising. This means significantly greater demands on the quality
of gearing. We are also exposed to high cost pressures, and are
continuously looking for new ways of increasing efficiency.”
In hobbing, feed and cutting speed are the primary factors.
Conventional hobs made from high-speed steel which is manufactured using powder metallurgy processes (HSS-PM) are, however,
reaching their limits in this respect because the tools made in this
way become too hot at high speeds. Yet the step up to hobs made of
carbide, which are suitable for high temperatures, is too expensive
for many users. These tools are more difficult to handle, and
require comprehensive process changes.
“We aim to make as many workpieces as
possible using each single tool.”
Ralf Schneider, Master of Process Optimization at CIT
SpeedCore:
premiere
at Varroc
Engineering
Varroc Engineering is a subsidiary of India’s Varroc
“It’s a clear case for SpeedCore,” says Torsten Oellers of LMT Fette,
an application engineer who works all over the world, including
for CIT. “What is special about SpeedCore is that it is harder at
high temperatures than HSS-PM. This allows us to increase cutting
speeds by 30 to 40 percent, and without users having to change
anything in their processes.”
According to Schneider, easy handling was one of the key factors
for CIT when they decided to switch to SpeedCore. “We require
particularly flexible tools. Our aim is to reduce the number of hobs
we have to use. This means that we try to make as many different
workpieces as possible using each single tool. SpeedCore is
outstanding in that respect.” A total of 20 different gears are made
in Paderborn using the new hobs. This is done using tools in sizes
ranging from module 3 to 6. Cutting speeds compared with
conventional HSS-PM hobs have risen by around 40 percent in each
case – while service life has remained constant. The cost per gear
has dropped by as much as 20 percent in some cases. Ralf Schneider
has also solved the problem of chip overflow as well – using larger
filling containers.
Group. At its factory in Pune this globally active automobile parts supplier manufactures engine and gearbox
parts. The company has been working together with
LMT Tools India for more than ten years now, much to
the satisfaction of Santosh R. Kulkarni, Workshop
Manager at Varroc in Pune: “LMT Tools are our first
choice when it comes to anything to do with gear
cutting. This is because of their technical quality, but
also because they are so quick to help us on site.”
Varroc has been one of the first customers in India to
utilize the new SpeedCore hobs. The company uses
them to manufacture output shafts for gearboxes made
of case-hardened steel (16MnCr5) on a Liebherr LC150
hobbing machine. Daily production output using the
previous HSS-PM hob was 2,300 units. By using the
SpeedCore hob, Varroc has increased cutting speeds
from 180 m/min to 270 m/min, and axial infeed from 1.3
to 1.6 mm. “This has allowed us to raise our production
output by more than 30 percent to over 3,000 units a
day,” explains Santosh R. Kulkarni. “We have also been
able to reduce our machine costs and cut our set-up
times as well.” It has been a successful premiere for
SpeedCore at Varroc.
Direct contact:
E-mail: [email protected]
11
EXCELLENT CONNEC
ROLLING API THREADS
Mexico is one of the world’s ten largest oil producing
nations. At the beginning of 2012, the global Tenaris Group
BACKGROUND: API THREADS
began to produce sucker rods in its steel mill in Veracruz,
API stands for American Petroleum Institute. The technical
these rods being used in subsurface pumps. The special-
guidelines published by the API represent a standard
ists from LMT Tools played a part from the outset. They
governing items of equipment used in the oil and gas industry.
equipped the Tenaris Tamsa production line with LMT
For the production of sucker rod threads compliant with the
Fette rolling heads. Special tools are used to manufacture
API standard, LMT Fette developed a completely new stand-
the threads at each end of the sucker rods.
ard rolling head. The F5-API-SR, and its associated rolls,
are available permanently on store at LMT. The API range is
Tenaris Tamsa manufactures around a million sucker rods in
Veracruz each year. That means two million threads produced
in a clamping system on each of the machines at the production
facility.
A total of 15 LMT Fette rolling heads are used at Veracruz.
They decided to work with LMT Tools following the successful
use of these rolling heads at a Tenaris factory in Argentina, as
Tilo Knobelsdorff, who is responsible for the project at LMT,
explains. “We first made contact with Tenaris in 2010 through
12
completed by special forming taps used to produce internal
threads on the connectors that join up sucker rods.
our sales partner, SIN PAR. Following intensive testing in
Argentina we received the order to manufacture the original
equipment for the plant at Veracruz.” There, rolling heads and
rolls are used in compliance with LMT Tools specifications. The
results speak for themselves. Service life is up to ten times
longer, and tool costs correspondingly lower.
LMT Fette –
number
one for
rolling
Thread rolling is the fastest, most precise, and most
efficient method of producing an external thread on
cold-formable material. Ever since the first thread
rolling head was made in 1951, LMT Fette has been
driving the development of this process. The roll
specialists have establish themselves worldwide as a
technology-leader, offering the most comprehensive
range of rolling heads, rolls and forming taps there is.
TIONS
LMT Fette tools can be used to produce almost every
standard thread type and specialized thread, ranging
in diameter from 1.4 to 230 mm – from cylindrical and
conical V-threads, to trapezoidal, round, and semiround threads. Specialized rolls can be used to burnish, flange, and press workpieces.
“This project is driven by technology,
our expertise, and our proximity to the
customer.”
Tilo Knobelsdorff, LMT Tools
Beyond the tools themselves, LMT Fette offers a
range of additional services. These include engineering custom tool solutions, roll tests on customer
Another reason why they chose LMT Tools was because of the
comprehensive on-site support. “I go to Veracruz at least once a
year in order to train operators in how to use the rolling heads,
and to discuss new projects. Our colleagues at our partner
company Boehlerit, who represent us in Mexico, take care of
ongoing on-site support. The project is driven by technology,
our expertise, and our proximity to the customer,” sums up Tilo
Knobelsdorff. Excellent connections indeed – but they don’t
stop there. The first LMT Fette rolling heads are now being used
at Tenaris plants in Brazil and Romania.
components, and training people at the Technology Center belonging to the LMT Group Academy in
Schwarzenbek, as well as global on-site assistance by
specially trained application technicians belonging to
the LMT Tools network.
Direct contact:
E-mail: [email protected]
13
THREE QUESTIONS FOR …
Hanjo GiSSler
Product Manager for Mould and Die
Construction at LMT Tools
What does “efficiency”
mean to you at Mould
and Die?
The contour produced in a mould in the end determines
precisely the shape of the component which it is used to
make. Even the smallest deviation can impair quality and
incur enormous costs. What is involved is the utmost
precision in a complex process chain, and that begins with
our tools.
What effect does that have on tool
development?
We always look at the whole process, and we adapt the
cutting materials, tool geometry, coating, and cutting edge
preparation to a customer’s particular requirements. For
example: two years ago we opened a new coating center in
Lahr, which made us the first manufacturer in the world to
be able to offer high-performance coatings specially tailored
to the demands of Mould and Die.
Can you describe that for us in more detail?
In coatings, there is a trend towards the development of
application-specific layers. We combine our experience with
the opportunities presented by modern coating systems, and
build up the layers we need from scratch. Our Nanomold
Gold launched in 2011 combines a top layer which is suitable
for high cutting speeds, with a core layer which retains its
properties even at low circumferential speeds. Nanomold Red
now represents the first layer ever made for hard machining.
These innovations have helped us to increase performance
and process safety, helping our customers in turn to achieve
competitive advantages.
PREMIER
Nanomold red triples the service life of tools in die and
Mould and Die construction is to tools what the Champions
League is to soccer players: rarely is so much demanded of
them. The materials that need to be machined have often
already been hardened. At the same time, users demand
the greatest accuracy and absolute process reliability –
users such as the Italian company Unimolds S.r.l.
Direct contact:
E-mail: [email protected]
14
LMT-Kieninger customer Unimolds demonstrates that Premier
League demands require players who regularly set new stand-
Technical specifications
Material: 1.2344 44HRC
Parameters: WPR-12-SF LCH33M
Vc: 294 m/min
n: 7800 rpm
fz: 0.15 mm
Vf: 2350 mm/min
ap: 0.15 mm
ae: 0.1 mm
Emulsion
te: 600 min/10h
+ ~ 56% service life
In Nanomold Gold, different
layers are combined with
one another.
LEAGUE
mould making
ards. With a WPR SuperFinish geometry, the copy milling process is used here to machine a mould for casting machines and
furnaces. Nanomold Red – the world’s first coating to be developed specially for hard machining in Mould and Die construction – raised the service life of the tool from approximately 3.5
hours to 10 hours. Almost tripling the service life meant a considerable economic boost for Unimolds.
Specialized coatings for Mould and Die
Nanomold Gold
Coatings based on nanocomposite technology are suitable
for roughing and the semi-finishing of soft alloyed and highalloyed tools steels, steel, gray cast iron, and nodular cast
iron. Nanomold Gold has a top layer optimized for high cutting
speeds, and a core layer for low circumferential speeds on
indexable inserts.
Nanomold Red
This high-performance coating is specially designed for
finishing cold and hot forming tool steel and cast steel,
and for machining hardened materials up to 65 HRC.
15
SPIRIT OF OPTIMISM
Production facility opened in India
India, like China, is one of the world’s fastest-growing economies.
Demand in the Indian automobile and parts supply industry for
modern production technology is especially high. LMT Tools has
had its own subsidiary representing it in India since 2001. Since
2011 the company, which is based in Pune in the west of the
country, has been operating its own dedicated hob production
facility. On September 6, 2013 a completely new production site was
ceremonially opened in Pune. The aim of this newly built
production facility in one of the centers of the Indian automotive
industry is to orientate production more effectively around the
demands of the Indian market, and to provide customers there
with a comprehensive service. The site extends over 6,000 square
meters and has modern administrative and training buildings in
addition to its tool production plant.
1
1 Modern:
In the factory building at the
new facility in Pune
2
16
2 Ceremonial:
Venkat Venkatasubramanian,
Managing Director of LMT Tools India,
welcomes guests at the opening.
3
3 Performers:
Hobs manufactured
in Pune.
4
4 Confident:
Franziska Eichel (left) and Angelika
Bengel, LMT Group shareholders,
plant a tree to mark the opening.
Series 34-028
Series 34-100
Specialized tools for
machining honeycomb
materials
Series 34-046
Series 68-000
LIGHTWEIGHT AND STABLE
Optimized machining of honeycomb sandwich panels for the aerospace industry
Lightweight construction is growing
inexorably, especially in the aerospace
industry. LMT Onsrud – a member of
the LMT Tools group – has adapted its
range of tools to meet new demands
and market requirements, and now
offers tools for almost every application involved in machining honeycomb
panels.
Generally speaking, two kinds of honeycomb panels are used to build aircraft, and
these exhibit different strength properties
because of the different areas in which they
are used. Structure panels, as they are
called, are used in the outer skin of aircraft, and inner panels are used to build
galleys and storage surfaces. For these two
applications, LMT Onsrudhas developed
specialized T-slot cutters (series 34-000)
and insert cutters (series 34-100). These
tools are characterized by variable cutting
heights and replaceable cutting edge parts.
They allow you to manufacture complete
components with minimum tool expenditure.
The T-slot cutters are unique in that they
can cut through the cover layer and undercut the honeycomb structure in one step.
They consist of an indexable nib of 22.3
mm diameter, and a 12.7 mm holder coated in PCD. The difference between the two
diameters produces a cutting edge overhang of 4.76 mm on each side, meaning
that the edge of the cover layer is effectively undercut by 5 mm, thus opening up the
neighboring honeycomb cell to the run
of the cut. The undercut is then treated
with a grouting compound and allowed to
harden.
Using another LMT Onsrud tool, the PKD
2 cutter (series 68-000), the cover layer and
honeycomb structure are cut in a single
step, producing a component which in
terms of its quality is then ready for installation.
cut, into which the attachment elements
are cast. After insertion from one side,
these attachment elements are filled with
grouting compound via a hole in the insert, and vented via a second drilled hole
so that the hollow space created by undercutting is completely filled.
The insert mills are made in different
heights for special standard panel thicknesses, such as 6.35 mm, 9.50 mm, and
so on. Several removable cutting bodies
are available for the T-slot cutters, in a
range of thicknesses for different core
thicknesses.
Both of the standard tool systems described here can be used for all cutting
depths, in conjunction with custom core
heights. Special tools are also produced
to customer requirements.
The insert mills produce a drilled hole of
the size of the attachment element involved. With an offset shaft, they can also
be used to produced holes with an under17
service
On location for LMT customers
Tool
management
The key to efficient tool logistics
Much in a company depends on a
functional tool management system.
Behind the supply of tools lies a complex system which ensures high levels
of process reliability. Only if a tool
LMT team supports the customer on
location, working to constantly optimize
production processes and tools. Many
intermediate configurations of services lie
between the two.
Engineering, tool
management,
technical support,
tool coating and
refurbishing – in the
global LMT Tools
service network,
our customers all
over the world have
access to precision
tool experts.
is provided at the right time in the
right place can production continue
smoothly. Procurement and warehousing costs can also be reduced considerably if this works well.
LMT tool experts plan and manage tool
supply for a very wide range of companies
and industries. These include large
automotive plants, as well as medium-sized
and smaller enterprises, for whom LMT
Tools has developed a special Kanban
system.
Which service the customer chooses
depends very much on his particular
requirements. LMT’s experts have
developed a five-level system. The basic
solution provides continuous procurement
of tools. Service level 5 encompasses a
complete service in which a dedicated
No matter what level of service a customer
requires, the following benefits will always
apply:
• Customized offerings at five service levels
• 100 percent cost control
• Potential efficiency utilized to the full
• Reduction of working capital
• Services from a single source
• High-level advice from LMT experts
Tool Management
GUARANTEES EFFICIENCY
China
LMT China Co. Ltd.
No. 8 Phoenix Road,
Jiangning Development Zone
211100 Nanjing
Telefon +86 25 52128866
Telefax +86 25 52106376
[email protected]
Using a tool management system
generally achieves lasting savings.
This was the conclusion arrived at
by experts at the consultancy company CIM Aachen GmbH when they
analyzed the potential open to a
medium-size company operating five
machining centers and 30 individual
machines. For an annual order volume
The Kanban modular service package
is aimed primarily at small companies.
On the basis of a standard range, this
system provides custom tool support.
LMT experts offer a collect and bring
service, ensuring that the tool range
defined beforehand is dependably
available. To customers this means
absolute process security in their
production.
18
of €600,000 to €700,000 for tools and
tool components, the introduction of
a tool management system achieved
the following:
... reduced number of tools
by 20 percent
... reduced tool consumption
by 15 percent
... increased machine utilization
by 5 percent
Source: VDI-Z 147 (2005), No. 3/March
kanban
Brasilien / Brazil
LMT Boehlerit Ltda.
Alameda Caiapós, 693
Centro Empresarial
Tamboré
06460-110 – Barueri
São Paulo
Telefon +55 11 55460755
Telefax +55 11 55460476
[email protected]
Deutschland / Germany
LMT Tool Systems GmbH
Heidenheimer Strasse 84
73447 Oberkochen
Telefon +49 7364 9579-0
Telefax +49 7364 9579-8000
[email protected]
Frankreich / France
LMT Belin France S.A.S.
Lieu dit „Les Cizes“
01590 Lavancia
Telefon +33 474 758989
Telefax +33 474 758990
[email protected]
Großbritannien und Irland /
United Kingdom
LMT UK Ltd.
5 Elm Court
Copse Drive
Meriden
CV5 9RG
Telefon +44 1676 523440
Telefax +44 1676 525379
[email protected]
service international
ers
Italien / Italy
LMT Italy S.r.l.
Via Bruno Buozzi 31
20090 Segrate (MI)
Telefon +39 02 2694971
Telefax +39 02 21872456
[email protected]
Korea
LMT Korea Co. Ltd.
Room #1212, Anyang Trade
Center
1107 Bisan-Dong, Dongan-Gu,
Anyang-Si,
Gyeonggi-Do, 431-817,
South Korea
Telefon +82 31 3848600
Telefax +82 31 3842121
[email protected]
Mexiko / Mexico
LMT Boehlerit S.A. de C.V.
Ave. Acueducto No. 15
Parque Industrial
Bernardo Quintana
76246 El Marqués, Querétaro
Telefon +52 442 2215706
Telefax +52 442 2215555
[email protected]
Rußland/Russia
ООО LMT Tools
Kotlyakowskaya str. 3
115201 Moscow
Telefon +7 495 510-1027
Telefax +7 495 510-1028
[email protected]
Singapur / Singapore
LMT Asia PTE LTD.
1 Clementi Loop 04-01
Clementi West District Park
Singapur 12 9808
Telefon +65 64 624214
Telefax +65 64 624215
[email protected]
Ungarn / Hungary
LMT-Boehlerit Kft
Kis-Duna U. 6
2030 Erd
Po Box # 2036 Erdliget Pf. 32
Telefon +36 23 521910
Telefax +36 23 521919
[email protected]
USA
LMT USA Inc.
1081 S. Northpoint Blvd.
Waukegan, IL 60085
Telefon +1 847 6933270
Telefax +1 847 6933271
[email protected]
Spanien und Portugal / Spain and Portugal
LMT Boehlerit S.L.
C/. Narcis Monturiol 11-15
08339 Vilassar de Dalt
Barcelona
Telefon +34 93 7507907
Telefax +34 93 7507925
[email protected]
LMT Technology Group
LMT Belin France S.A.S.
Lieu dit „Les Cizes“
01590 Lavancia
Frankreich
Telefon +33 474 758989
Telefax +33 474 758990
[email protected]
www.lmt-belin.com
Tschechische Republik
und Slowakei/ Czech Republic and Slovakia
LMT Czech Republic s.r.o.
Dusikova 3
63800 Brno-Lesná
Telefon +420 548 218722
Telefax +420 548 218723
[email protected]
LMT Fette Werkzeugtechnik
GmbH & Co. KG
Grabauer Strasse 24
21493 Schwarzenbek
Deutschland
Telefon +49 4151 12 - 0
Telefax +49 4151 3797
[email protected]
www.lmt-fette.com
LMT Kieniger GmbH
Vogessenstrasse 23
77933 Lahr
Deutschland
Telefon +49 7821 943 65 0
Telefax +49 7821 943 65 213
[email protected]
www.lmt-kienunger.com
LMT Onsrud LP
1081 S. Northpoint Blvd.
Waukegan, IL 60085
USA
Telefon +1 847 3621560
Telefax +1 847 4731934
[email protected]
www.lmt-onsrud.com
in alliance
Bilz Werkzeugfabrik
GmbH & Co. KG
Vogelsangstrasse 8
73760 Ostfildern
Deutschland
Telefon +49 711 348010
Telefax +49 711 3481256
[email protected]
www.bilz.com
Boehlerit GmbH & Co. KG
Werk-VI-Strasse
8605 Kapfenberg
Österreich
Telefon +43 3862 300 - 0
Telefax +43 3862 300793
[email protected]
www.boehlerit.com
www.lmt-tools.com
Indien / India
LMT (India) Private Limited
Old No. 14, New No. 29,
Ilnd Main Road
Gandhinagar, Adyar
Chennai – 600 020
Telefon +91 44 24405136/137
+91 44 42337701/03
Telefax +91 42337704
[email protected]
Polen / Poland
LMT Boehlerit Polska Sp. z.o.o.
ul. Wysogotowska 9
62-081 Przezmierowo
Telefon +48 61 6512030
Telefax +48 61 6232014
[email protected]
Türkei / Turkey
BÖHLER Sert Maden
ve Takim Sanayi ve Ticaret A.Ş.
Ankara Asfalti Üzeri No. 22,
Kartal 34873
Istanbul
Telefon +90 216 306 65 70
Telefax +90 216 306 65 74
[email protected]
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