Special tools for customer applications

HOLLFELDER-GÜHRING CUTTING TOOLSYour competent partner in the area of metal chip removal
At our two company locations in Nuremberg und Zorbau (Germany) we design and manufacture precision
tooling for highest quality demands on state-of-the-art CNC-turning / milling / grinding and EDM machines.
All activities in our enterprise are based on our corporate quality and environmental policy and aim to contributeto a permanent increase in our customers productivity while observing all applicable legal and governmental
regulations.
Additionally we strive to achieve a leading position in our sector with our products and services and to continuously improve this position by means of a high level of quality as well as an adequate environmental policy.
All processes in our enterprise are mainly based on our customers demands and are always supervised by the
management team and adapted to the changing general conditions by continuous improvement processes(CIP). In order to achieve our targets we maintain a certificated quality and environmental system according to
DIN EN ISO 9001 : 2008 and DIN EN ISO 14001 : 2004.
The perfect composition of highly qualified staff and most modern production methods constitutes the basis
for fully developed products on a high quality standard.
The easy handling and the adjustability of our milling cutters are the basis for savings in the area of tool presetting as well as for achieving tight tolerances.
Our standard program constitutes the basis for a huge number of innovative special tooling solutions which getused and appreciated at our customers globally. In many cases it is the customers specific solution which
opens up the full potential of our tooling systems and thus contributes to savings and increases in productivity.
We would be happy to advise you in selecting the right tooling solution for your specific application and to stayon your side as your competent partner from the start of process planning until the effective use of our tools.

Challenge us with your requirements!
precise | flexible| innovative
We always appreciate your confidence in us.

Headquarters Nuremberg

2

Location Zorbau

Introduction

A reliable partner
HOLLFELDER-GÜHRING CUTTING TOOLS
has achieved a leading position as a reliable partner in the metal cutting industry. Innovative tooling solutions
in standard tools as well as in tools made to customers specifications constitute the basis for cost optimised
production.
Competence
Individual solutions for complex machining problems, tailor-made to the individual requirements are part of theself-image of our technicians and engineers. With a high qualification and an innovative thinking combined witha lot of experience, we design and manufacture in close contact with our customers tooling systems of highest
precision for the μm-accurate machining of complex contours.
Profitability
HOLLFELDER-GÜHRING CUTTING TOOLS offers profitable solutions. The easy adjustment of our tools reduces
non-productive times. We achieve a reduction in machining times due to our intelligent combined tools, thehigh number of effective teeth and the selection of the optimal cutting grade. The advantages are the utmost
flexibility, productivity and certainty in process.
Our service
Depending on the technical requirements we analyse the machining processes and suggest tooling solutions
which satisfy the high demands of our customers. With the proven tooling solutions of HOLLFELDER-GÜHRING
CUTTING TOOLS our customers use highly precise and reliable systems which have achieved an excellent
reputation worldwide.
Our service spectrum includes among others:• In-house machining tests• Application training also on-site at the customer‘s premises• Complete CAD-layouts according to customer specifications• Technical support
Our targets...
…are to steadily increase the efficiency of our precision tools as well as their operational possibilities. Thus ourcustomers are leading obtain a competitive advantage due to the more efficient production with a high certainty
in process.

For further information
visit our website
www.hollfelder-guehring.de3

Contents

6 Adjustment systems

Adjustment systems for our tools

Customer specific tools for machining the workpieces
mentioned below:

10 Cylinder head

Pre- and finish-machining, fire face, bearing passage, bearing width,
axial grooving, spring seat, spark plug bore, relief bore, induction port

24 Cylinder crankcase

Pre- and finish-machining, bearing width, sealing surface, ventilation bore,
connecting bore, balance shaft bore, bearing cap, crankshaft bore,
cylinder bore, cylinder liner, clearance cut for the honing tool,
crankshaft bearing passage

46 Gearbox components

Valve body, gearbox case, pre-machining, shoulder machining,
connecting shank, bearing seats, valve plate

56 Electric motor
Stator bore

4

Contents

60 Pumps

Oil pump, injection pump, stainless steel pump

74 Further components for automotive industry

Starter housing, camshaft, crankshaft, frame, gearshift fork, axle carrier,steering housing, drive flange, balance shaft housing, brake caliper,
control housing, gearbox case, balance shafte, connecting rod

92 Components of general engineering

Power tools, hydraulic industry, wind power industry,end machining, compressor construction industry

108 Turbocharger housing

Pre- and finish-machining, V-band

118 Aviation technology

Fuel manifold, aircraft components

122 Turning

Camshaft regulator, case, profil shaft, bearing bracket, shaft

128 Enquiry forms

5Adjustment systems
Eccentric pin adjustment

The adjustment systems in the tools constitute the basis
for highly precise production results in the most different materials.
They are the basis for innovative tooling designs which contributeenormously to the productivity of our customers.
The application is simple and saves time.

µm• Eccentric pin for µm-accurate adjustment• Many design options thanks to open construction• Design of the clamping system doesn‘t require any support on the side of the pocket seat
• Triangular machining is possible• Insert can be adjusted in 2 directions

Adjustment range
Eccentric pin

Eccentricity

InsertEccentric pin
Tool

Clamping element

Hexagon drive

InsertA

A
Adjustment key (hex key)
to operate the eccentric pin

Eccentric pin
Clamping
element6

Adjustment systems
Radial screw adjustment and adjustment with tapered screwµm• Radial screw adjustment for µm-accurate diameter adjustment• Large range of adjustment up to 2 mm in diameter• Easy handling thanks to robust design

Large chip flute
Adjustment element(pushing screw)

Adjustable
up to 2 mm

Set screw

Thrust transmitting piece

Central position of the insert• µm-accurate diameter adjustment with tapered screw• Adjustment possible from the front and from the top• Can be flexibly combined and usedµm
µm

Adjustment element(tapered screw / torx
or hexagon socket)

0,02 ShankØ µm-accurate adjustable
Adjustment from the front

Adjustment from the top

7Adjustment systems
Micro-adjustment

The micro-adjustment can be considered as the logical next stepin the development of the tapered screw adjustment from the front.
A built-in adjustment cartridge in the holder enables the user
to achieve an extremely precise adjustment of the machining measuresµm
1 revolution
0.02 mm in Ø8

• Adjustment element can be integrated even for small bore diameters• Advantageous adjustment relation 1 revolution 0,2 mm in Ø
• µm-accurate adjustment directly in the machining center• Low machine downtime

Adjustment systems
SMART SETTING MOTION TOOLS adjustment

Smart
Setting
MotionTools

55 60 5
10
50
45
40

15
20

Pre-setting
and re-adjusting of inserts
35 30 25

within seconds• Individual fine adjustment of all finishing inserts.
One graduation line equals 0.002 mm in diameter• Diameter adjustment in both directions, plus and minus• No special equipment required for pre-setting (i.e. magnetic V-gauges)• Cartridges available with eccentric adjustment, also available with standard
ISO insert• Option: retraction of the inserts via drawbar
no workpiece adjustment required• Option: mechanical operation, using either compressed air or machine coolant• Time saving of more than 90% per setting cycle

Central adjustment• Simple pre-setting without special equipment• Cartridges available with eccentric adjustment, also available with standard
ISO insert• Diameter adjustment in both directions, plus and minus via central adjustment
screw• Automatic readjustment if required. One rotation equals 0.03 mm on radius• Retracting of the finishing cartridge by means of compressed air• Expanding of the finishing cartridge inside the honing undercut

Different adjustment screws

9Cylinder
head

10

Cylinder headPre-machining

HPC rough milling cutter Ø 163 / L = 232 mm / HSK80-A / Teeth = 18

Integrated
coolant exit

Adjustable
PCD inserts

Requirementss
Reduction of cycle times
Solution
HPC rough milling cutter Ø 163 / L = 232 mm / HSK80-A / Teeth = 18
Cutting data
(DIN) AlSi10Mg(Cu) heat-treatedMaterial
Cutting grade
PCD 30Cutting speed
m/min
3,000
Feed rate per toothmm
0.14
Cutting depthmm-6Result
50% faster than competitors			
Longer tool life
Lower power consumption

Customer benefits
Reduced tooling costs per component
Almost chip-free components, lower cleaning costs
Increased productivity and energy efficiency

11

Cylinder head
Finish-machining

HPC milling cutter with closed chip flutes / Ø 250 reduced weight
Teeth = 21 + 3 mixure of inserts / Use of wiper inserts

Secure chip
evacuation

Requirements
Chip-free components
Solution
HPC milling cutter with closed chip flutes
Cutting data
(DIN) AlSi10Mg(Cu) heat-treatedMaterial
Cutting grade
PCD 30Cutting speed
m/min
3,500
Feed rate per toothmm
0.12
Cutting depthmm
0.5
Result
50% faster than competitors
Longer tool life
Higher surface finish quality

Customer benefits
Reduced tooling costs per component
Almost chip-free components, lower cleaning costs
Increased productivity and energy efficiency

12

Cylinder head
Fire face

HPC bar cutter Ø 315 with HSK-A100 / Teeth = 4 + 4 / Teetheff. = 8
Radially adjustable cartridge

Integrated
coolant exit

Compensation unequal flute spacing

Carbide chip
guiding element

Requirements
Combustion chamber milling, required cutter diameter 315 mm
Rz 6.3 - Rmax 7 - Wt3 - PMr 65 %Critical capability index Cmk 2.74
Maximum permissible tool diameter 250 mm
Solution
HPC bar cutter Ø 315 with HSK-A100 / Teeth = 4 + 4 / Teetheff. = 8
Cutting data
(DIN) GD-AlSi9Cu3
Material
Cutting grade
PCD
Cutting speed
m/min
2,177
Feed rate per toothmm
0.13
Cutting depthmm
0.28
ResultUniform surface
Rz 1,4 - Rmax 1,67 - Wt 1,28 - PMr 100 %Customer benefits
High-precision machining can be carried out on a standard machining center(no special machine required)
Almost chip-free components, lower cleaning costs

13

Cylinder head
Bearing passage

Gang milling cutter / Teetheff. = 2

Full cutµm

bearing19
adjustable

Requirements
Clearance milling, face run-out and milling cutters are adjustable towards each other
Solution
Gang milling cutter / Teetheff. = 2
Cutting data
(DIN) G-AlSi9Cu
Material
Cutting grade
PCD
Cutting speed
m/min
220
Feed rate per toothmm
0.07
Cutting depthmm
0.7 - 0.8
Result
PCD inserts regrindable and renewable
Narrow tolerances of bearing spacings achievable
Minimal effort for insert change

Customer benefits
Reduced tooling costs per component
Low non-productive times

14

19
adjustablebearing19
adjustabCylinder head
Bearing passageble

19
adjustableØ 52.5 ±0. 05

Ø 58.5 ±0. 05

t19
adjustable
60 ±0.1 adjustable
124 ±0.1 adjustable
142 ±0.1 adjustable

212 ±0.1 adjustable
230 ±0.1 adjustable

15

Cylinder head
Bearing width

Gang milling cutter / Teeth = 2 x 4

HSK 63-C

Ø 37 ±0.05

Ø 50 ±0.05

Ø 25

µm

20.894
adjustable

0.5 x 45° adjustable

85.894
adjustable

0.5 x 45° adjustable

Requirements
Gang milling cutter for milling the bearing width with chamfering
Bearing width and chamfer sizes μm-accurate adjustable
Solution
Gang milling cutter / Teeth = 2 x 4
Cutting data
(DIN) GKAlSi7Mg
Material
Cutting grade
PCD
Cutting speed
m/min
1,200
Feed rate per toothmm
0.1
Cutting depthmm
2.5
Result
PCD inserts regrindable and renewable
Narrow tolerances of bearing spacings achievable
Minimal effort for insert change
Reduced machining time thanks to combination tool

Customer benefits
Reduced tooling costs per component
Low non-productive times

16

Cylinder head
Axial grooving

Reaming tool / Teeth = 1

run out check diameterrun out check diameter

5x guide pads PCD

Ø 70(Ø 25.8 ±0.001)µm

95Requirements
Fine machining with PCD guide pads
Solution
Reaming tool / Teeth = 1
Cutting data
(DIN) Al
Material
Cutting grade
PCD
Cutting speed
m/min
800
Feed rate per toothmm
0.1
Cutting depthmm
0.3
ResultNarrow form and position tolerances are maintained
Surface finish quality Ra 0.5

Customer benefits
Higher process reliability
Easy adjustment of the inserts

17

Cylinder head
Spring seat

Drilling and countersinking tool / Teeth = 2
Profile inserts adjustable and separately replaceableØ 22.8

Ø 10

Ø 21.6

Ø 9.5

R
0. 2

45°

R
0.4

0.5

2.2
30°

Requirements
Complete machining of the hole including the spring support
Solution
Drilling and countersinking tool / Teeth = 2
Profile inserts adjustable and separately replaceable
Cutting data
(DIN) AlSi10Mg(Cu)Material
Cutting grade
PCD 10Cutting speed
m/min
590
Feed rate per toothmm
0.075
ResultTool life 85,000 drilled holes
SC-drill regrindable several times

Customer benefits
Lower tool costs per part compared to brazed tools

18

Cylinder head
Spring seat

Form countersinking tool with PCD inserts and integrated SC-drill /Teeth=2

Ø 29.4 adjustablez=2
Ø 26.1
Ø 17.5Ø 10

140°Requirements
Machining of the complete workpiece contour with one tool
Solution
Form countersinking tool with PCD inserts and integrated SC-drill / Teeth=2
Cutting data
(DIN) AlSi9Cu
Material
Cutting grade
PCD
Cutting speed
m/min
850
Feed rate per toothmm
0.15
Cutting depthmm
4.3
ResultHigh tool life (>70,000 drilled holes) with simultaneous compliance oftolerances and surface requirements

Customer benefits
Short processing time
Lower costs per workpiece

19

Cylinder head
Spring seat

Multi-step fine boring tool / Teeth = 2 per Ø

HSK 63-Aµm

Ø 11

Ø 32.5 adjustableØ 33.9 adjustableµm

107
123 adjustable

Requirements
Drilling and fine boring of the spring seat
Drill length adjustable, fine boring diameters adjustable
Solution
Multi-step fine boring tool / Teeth = 2 per Ø
Cutting data
(DIN) GG25
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 11) 88 / (Ø 33.9) 258
Feed rate per toothmm
0.07
Cutting depthmm-5ResultSC-drill regrindable several times
Inserts adjustable and separately replaceable

Customer benefits
Reduced tooling costs per component compared to solid carbide tools

20

Cylinder head
Spark plug bore

Multi-step fine boring tool / Teetheff. = 1

HSK 63-A
Ø 7.5 adjustableØ 21.1 adjustableµm

Ø 25.7 adjustableµm205.75

222.7

241Requirements
Pre-machining, form inserts for special profile
All inserts adjustable
Solution
Multi-step fine boring tool / Teetheff. = 1
Cutting data
(DIN) GG-Cr
Material
Cutting grade
carbide coatedCutting speed
m/min
220
Feed rate per toothmm
0.07
Cutting depthmm0.2-0.8
ResultInserts adjustable and separately replaceable

Customer benefits
Reduced tooling costs per component compared to solid carbide tools

21

Cylinder head
Broaching of relief groove

Broaching tool / Teeth = 1

Requirements
Reduction of tool costs and machining time
Elimination of expensive special milling cutters
Solution
Broaching tool / Teeth = 1
Cutting data
(DIN) AlSi10Mg(Cu)Material
Cutting grade
PCD
Cutting speed
m/min
25
Cutting depth
mm
0.5 per stroke
ResultLong tool life thanks to constant cut
Low tooling costs
Significant reduction in machining time

Customer benefits
Lower machine investment - no expensive milling spindle (high-speed)
Reduced tooling costs per component

22

Cylinder head
Induction port

Induction port milling tool / Teeth = 2
PCD inserts adjustable and replaceable

Carbide shankØ 27 adjustable
Z=2

Ø 25 h6

Machining plan
depth of cut 3 mm
forward and backward

µm

56.6
183

Requirements
Complete machining of the in-and outlet ducts
Solution
Induction port milling tool / Teeth = 2
PCD inserts adjustable and replaceable
Cutting data
(DIN) AlSi10
Material
Cutting grade
Cutting speed
Feed rate per tooth
Cutting depth
ResultHigh feed rates
Consistent surface finish

m/min
mm
mm

PCD 101,357
0.35
3 forward and backward

Customer benefits
Lower tool costs thanks to interchangeable inserts

23

Cylinder
crankcase24Cylinder crankcase
Pre-machining

HPC rough milling cutter / Teeth = 15 / up to 8 mm cutting depth

Firm clampingof the inserts

Requirements
Increase tool life
Minimization of edge breakouts on the component
Solution
HPC rough milling cutter / Teeth = 15
Cutting data
(DIN) AlSi17Cu4 T5 / T6
Material
Cutting grade
PCD 30Cutting speed
m/min
685
Feed rate per toothmm
0.14
Cutting depthmm~1.5
ResultTool life improvement by factor 4 to 5
Lower power consumption
No edge breakouts on the component

Customer benefits
Reduced tooling costs per component
Almost chip-free components, lower cleaning costs
Increased productivity and energy efficiency

25

Cylinder crankcase
Bearing width

Gang milling cutter / Teeth = 5 per milling cutter

185 adjustable
z=5

260 adjustable
z=5281 adjustable
z=5355 adjustable
z=5µm

378 adjustable
z=5455 adjustable
z=5

Face run-out and milling cutters adjustable to each other

Ø 158

7.8

bearing

Requirements
Milling of the bearing width
Face run-out and milling cutters adjustable to each other
Solution
Gang milling cutter / Teeth = 5 per milling cutter
Cutting data
(DIN) GD-AlSi9
Material
Cutting grade
PCD / K10
Cutting speed
m/min
500
Feed rate per toothmm
0.07
Cutting depthmm-5ResultQuick and easy changing of the inserts
Excellent surface finish
PCD inserts usable on both sides

Customer benefits
Reduced non-productive times
Half of the costs thanks to double-used PCD inserts

26

bearing

Cylinder crankcase

90 adjustable
z=5160 adjustable
z=5

Bearing width027Cylinder crankcase
Sealing surface

Face milling cutter / Ø 500 mm / Teeth = 52
Cartridge solution

Requirements
Milling of the sealing surface, Aluminium crankcase
All inserts adjustable
Solution
Face milling cutter / Teeth = 52
Cartridge solution
Cutting data
(DIN) GD-AlSi9
Material
Cutting grade
PCD
Cutting speed
m/min
3,000
Feed rate per toothmm
0.1
Cutting depthmm
0.5
ResultOutstanding tool life
Easy adjustment of the inserts

Customer benefits
Low costs per component
Reduced non-productive times

28

Cylinder crankcase
Milling thrust bearing seat

Milling cutter with vibration damper / Teeth = 16 / Teetheff. = 8

Requirements
Milling the bearing clearances for the crankshaft
Solution
Milling cutter with vibration damper / Teeth = 16 / Teetheff. = 8
Cutting data
(DIN) AlSi9Cu3
Material
Cutting grade
PCD
Cutting speed
m/min
516
Feed rate per toothmm
0.08
Cutting depthmm
1.5 - 8ResultAbsolutely vibration-free and high quality surface finish

Customer benefits
High tool life of PCD inserts thanks to smoth cutting performance

29

Cylinder crankcase
Milling thrust bearing seat

Milling cutter with integrated vibration damper / Teeth = 16 (8 + 8)

Requirements
Maximum number of cutting edges, vibration damped for high surface quality
Solution
Milling cutter / Teeth = 16 (8 + 8)
Cutting data
(DIN) AlSi12
Material
InsertPCD
Cutting speed
m/min
650
Feed rate per toothmm
0.1
ResultStable milling operation, surfaces free of vibrations

Customer benefits
Cycle time reduction thanks to high number of cutting edges
Excellent surface finish

30

Cylinder crankcase
Profile milling

Milling cutter with vibration damper / Teetheff. = 3

Ø 279.9

Ø 329

Ø 56

Requirements
Milling a slot in the bearing diameter
Extreme protrusion length
Solution
Milling cutter with vibration damper / Teetheff. = 3
Cutting data
(DIN) GG25
Material
Cutting grade
carbide coatedCutting speed
m/min
345
Feed rate per toothmm
0.03
Cutting depthmm
3.5
ResultSmooth cutting performance and good surface quality thanks to the use of a vibration damper

Customer benefits
High quality components

31

Cylinder crankcase
Ventilation boreØ 32 adjustableµmµm

Ø 31 adjustable

Drilling and fine boring tool / Teeth (drilling) = Teetheff. = 1 /(counterboring) = 2

HSK 63-A

103

run out check diameter

340

Requirements
Pilot tool with guide pads (drilling into solid - 1. web)
Finish tool with guide pads (drilling into solid)
Solution
Drilling and fine boring tool / Teeth (drilling) = Teetheff. = 1 / (counterboring) = 2
Cutting data
(DIN) GK-AlSi17Cu4Mg
Material
Cutting grade
K10 / PCD
Cutting speed
m/min
320
Feed rate per toothmm
0.07
Cutting depthmm
into solid / 0.5
ResultLonger tool life

Customer benefits
Process reliable production processes32Ø 33 adjustablez=2µm

Ø 31 adjustableµmØ 32 -0.003 adjustable
z=2

145

0.75 x 45°
HSK 63-A

Cylinder crankcase
Connecting bore

Drilling and fine boring tool / Teeth = 2 + 2 + 1

run out check diameter

Ø 70(Ø 15)(Ø 36.3) adjustablez=1

Ø 26.03 ±0.01 adjustablez=2

run out check diameter

µm

65
80
100

Requirements
Combination tool with solid carbide drill for boring andadjustable inserts for fine boring and chamfering
Solution
Drilling and fine boring tool / Teeth = 2 + 2 + 1
Cutting data
(DIN) Al
Material
Cutting gradePCD
drilling
Cutting speed
m/min
193
Feed rate per toothmm
0.3
Cutting depthmm
into solid
ResultConventional solid carbide drill, regrindable several times
Insert diameter µm-accurate adjustablefine boring
470
0.12
5.5

Customer benefits
Cost-efficient solution

33

Cylinder crankcase
Balance shaft bore

Line boring with cartridges and PCD-equipped pilot

Heavy metal holder with carbide guide pads for stabilisation

Requirements
Semi-finish machining with counter bearing in the component
All inserts adjustable
SolutionLine boring with cartridges and PCD-equipped pilot
Heavy metal holder with carbide guide pads for stabilisation
Cutting data
(DIN) AlSi9Cu3
Material
Cutting grade
PCD
Cutting speed
m/min
280
Feed rate per toothmm
0.12
Cutting depthmm
0.5
ResultHigh concentricity of bearing diameters
Simple tool handling

Customer benefits
High process reliability

34

Cylinder crankcase
Balance shaft bore

35

Cylinder crankcase
Bearing cap

Form milling cutter / Teeth = 2 x 6
Transition of the insert profile adjustable

HSK 100-AAØ 100
z = 12 ( Z eff. 6 )

µm

0.02

165

adjustable

Requirements
Form milling cutter for machining bearing caps
Solution
Form milling cutter / Teeth = 2 x 6
Transition of the insert profile adjustable
Cutting data
(DIN) GGG40
Material
Cutting grade
carbide coatedCutting speed
m/min
240
Feed rate per toothmm
0.1
Cutting depthmm1ResultLow cutting forces thanks to cutting division

Customer benefits
Cost-effective interchangeable inserts solution

36

Overlap

Cylinder crankcase
Crankshaft bore

Operation 1: counterboring tool / Teeth = 2

20

23

BT 50

Ø 52.5
z=2

20

215

Operation 2: fine boring tool / Teeth = 1
guide pads
Ø 52.7 adjustable
z=1

µm

BT 50

23
100
105

Requirements
Operation 1: pre-machining from 2 sides
Operation 2: pilot bore
Solution
Operation 1: counterboring tool / Teeth = 2
Operation 2: fine boring tool / Teeth = 1
Operation 1
Cutting data
(DIN) GG
Material
Cutting grade
carbide coatedCutting speed
m/min
150
Feed rate per toothmm
0.2
Cutting depthmm
2.5
ResultSimple tool handling thanks to eccentric pin adjustment
Guide pads easily replaceable

Operation 2

135
0.1
0.1

Customer benefits
Reduced non-productive times
High quality components

37

Cylinder crankcase
Crankshaft bore

Operation 3: fine boring tool / Teeth = 1 + 1

guide pads CBN

guide pads carbide

20.5
35

compensations adapter
BT 50

20

20

20
285
442
450

Requirements
Operation 3: finish-machining
Solution
Operation 3: fine boring tool / Teeth = 1 + 1
Operation 3
Cutting data
(DIN) GG
Material
Cutting grade
carbide coatedCutting speed
m/min
238
Feed rate per toothmm
0.1
Cutting depthmm
0.1
ResultSimple tool handling thanks to eccentric pin adjustment
Guide pads easily replaceable

Customer benefits
Reduced non-productive times
High quality components

38

run out check diameter(Ø 53.012 -0.003)
z=1

run out check diameter(Ø 52.7 -0.003)
z=1

µm

23

Cylinder crankcase
Cylinder bore

Boring tool with integrated vibration damper,
adjustable cartridges and ISO indexable inserts / Teeth = 5

KV400 KKH
axially adjustable

Requirements
Roughing operation
Ø 74±01
Solution
Boring tool with adjustable cartridges and ISO indexable inserts / Teeth = 5
Cutting data
(DIN) GG25
Material
Cutting grade
carbide coatedCutting speed
m/min
150
Feed rate per toothmm
0.2
Cutting depthmm
Ø 1 - 1.5
ResultVery good tool life
Stable machining process

Customer benefits
Low costs per component

39

Cylinder crankcase
Cylinder bore

Boring system GA 200 Vario /Teeth = 2 for roughing and finish-machining

44 -130 mm

ØRequirements
Roughing operation
Ø 72.5±0.2 Rz 100
Solution
GA 200 Vario / Teeth = 2
Cutting data
Material
Cutting grade
Cutting speed
Feed rate per tooth
Cutting depth
ResultIncreased tool life
Simple tool handling

(DIN)
m/min
mm
mm

Customer benefit
Low cost per component

40

GG
CBN
649
0.2
Ø 1.5 - 2

Motor block
Milling of clearance cut for the honing tool

Tight cutting edge spacing
Various cutting materials can be used
With a stable core cross-section, this robust
solution can achieve high feed rates

Requirements
Circular milling a clearance cut for the honing tool into the cylinder bore
Mixed machining Aluminium and Cast Iron
Solution
Circular milling cutter with fixed insert seat
Double positive cutting geometry
Cutting data
Material
AlSi9 / GG25
Cutting grade
PCD / PROTON coated carbide
Cutting speed
m/min
242
Feed rate per toothmm
0.18
Cutting depthmm
6-7
ResultShort machining time with high cutting depth

Customer benefits
Solid solution high feeds possible
Inserts can be changed individually
lower costs per component

41

Cylinder crankcase
Cylinder bore

Automatically adjustable tool / Teeth = 1
SMART SETTING MOTION TOOLS concept

Requirements
Simple tool handling
Solution
Automatically adjustable tool / Teeth = 1
SMART SETTING MOTION TOOLS concept
Cutting data
(DIN)
Material
Cutting grade
CBN
Cutting speed
m/min
750
Feed rate per toothmm
0.28
Cutting depthmm
0.3
ResultFully automatic diameter adjustment

GG25

Customer benefits
Increase in tool life quantity
Very easy handling and very precise adjustment

42

Cylinder crankcase
Cylinder liner

Automatically adjustable tool / Teeth = 3 + 2
SMART SETTING MOTION TOOLS concept
and control of the drawbar via compressed air

Requirements
Reduction of processing costs
Solution
Automatically adjustable tool / Teeth = 3 + 2
SMART SETTING MOTION TOOLS concept
Control of the drawbar via compressed air
Cutting data
(DIN) GG
Material
Cutting grade
CBN
Cutting speed
m/min
700
Feed rate per toothmm
0.18
Cutting depthmm
0.3
ResultSemi-finish and finishing machining in one tool
No retraction marks thanks to retractable inserts

Customer benefits
High process reliability
Simple tool handling

43

Cylinder crankcase
Crankshaft bearing passage

Line boring bar / Teeth = 5 + 5 / Teetheff. = 1 + 1
SMART SETTING MOTION TOOLS concept

Requirements
Reduced non-productive time and cycle time
Defined surface Rz 12 - 20
SolutionLine boring bar / Teeth = 5 + 5 / Teetheff. = 1 + 1
SMART SETTING MOTION TOOLS concept
Cutting data
(DIN) GG25
Material
Cutting gradesolid carbide
Cutting speed
m/min
185
Feed rate per toothmm
0.27 / 0.2
Cutting depthmm
0.5
ResultNon-productive times for re-adjusting reduced from 20 minutes to 2 minutes
Simple handling

Customer benefits
High process reliability
Dramatic reduction of non-productive time44

Cylinder crankcase
Crankshaft bearing passage

Machining direction

Bearing position 2>II< = 0.002 mm in Ø

Finish-machining

Semi-finish-machining

45

Gearbox
components

46

Gearbox components
Valve body

HPC gang milling cutter Ø 380 mm / Teeth = 2 x 33
Adjustable distance between milling cutters (Dimension 280 mm)

Secure chip
evacuation

Requirements
Machining of the sealing surface
Chip free components
Simultaneous machining of two components
Solution
HPC gang milling cutter Ø 380 mm / Teeth = 2 x 33
Adjustable distance between milling cutters (Dimension 280 mm)
Cutting data
(DIN) AlSi7
Material
Cutting grade
PCD
Cutting speed
m/min
780
Feed rate per toothmm
0.07
Cutting depthmm
0.5
ResultExcellent surface finish
Very good tool life

Customer benefits
Almost chip-free components, lower cleaning costs
Reduced tooling costs per component

47

Gearbox casePre-machining

Stepped countersinking tool Ø 206 mm + Ø 209 mm + Ø 285 mm /Teeth = 2 + 2 + 2

Basic tool body in steel and aluminium with cartridges

Light-weight
designRequirements
Minimization of tool weight and tool dimensions
Solution
Stepped countersinking tool / Teeth = 2 + 2
Basic tool body in steel and aluminium with cartridges
Cutting data
(DIN) AlADC10
Material
Cutting grade
PCD
Cutting speed
m/min
1,200
Feed rate per toothmm
0.12
ResultReduced tool weight

Customer benefits
Slim design saves space within the tool magazine of the machine
Low costs thanks to standard cartridges and ISO inserts

48

Gearbox casePre-machining

Stepped countersinking tool Ø 219 mm + Ø 220 mm /Teeth = 2 + 4

Basic tool body in steel and aluminium with cartridges

Light-weight
designRequirements
Minimization of tool weight and tool dimensions
Solution
Stepped countersinking tool / Teeth = 4 + 2
Basic tool body in steel and aluminium with cartridges
Cutting data
(DIN) AlADC10
Material
Cutting grade
PCD
Cutting speed
m/min
1,200
Feed rate per toothmm
0.1
ResultReduced tool weight

Customer benefits
Reduced machining times
Low costs thanks to standard cartridges and ISO inserts

49

Gearbox caseShoulder machining

Multi tooth cutter Ø 125 / Teeth = 36 / Teetheff. = 12

Top view

Requirements
High surface quality on face and shoulder surface
Solution
Multi tooth cutter / Teeth = 36 / Teetheff. = 12
Cutting data
(DIN) AlSi9Cu3
Material
Cutting grade
PCD 10Cutting speed
m/min
2,500
Feed rate per toothmm
0.12
Cutting depthmm
0.8
ResultAlmost uninterrupted shoulder thanks to high concentricity

Customer benefits
Inserts separately replaceable
Increased productivity and energy-efficiency

50

Gearbox case
Machining of a connecting shank

Combination tool with adjustable inserts eccentric pin adjustment / Teeth = 5 / Teetheff. = 1

Ø 41.566 z = 1
adjustableØ 41.366 z = 1
adjustableØ 9.989 z = 1
adjustable

Requirements
High concentricity requirements and concentricity of the individual diameters to each other
Adjustability of inserts
Solution
Combination tool with adjustable inserts - eccentric pin adjustment / Teeth = 5 / Teetheff. = 1
Cutting data
(DIN) AlSi9
Material
Cutting grade
PCD
Cutting speed
m/min
1,380
Feed rate per toothmm
0.15
ResultEasy readjustment of the inserts

Customer benefits
Reduced non-productive times
Cost-effective interchangeable inserts solution

51

Gearbox case
Bearing seats

Fine boring and circular milling tool / Teeth = 3 per Øµm

HSK 100-A

Ø 56 adjustableØ 66 adjustableØ 84 adjustable

µm

37

280

Operation 1

Requirements
Combination tool for fine boring and circular milling
Solution
Fine boring and circular milling tool / Teeth = 3 per Ø
Cutting data
(DIN) AlSi9
Material
Cutting grade
PCD
fine boring
Cutting speed
m/min
450
Feed rate per toothmm
0.08
Cutting depthmm-4ResultInserts separately replaceable

Customer benefits
Reduced tooling costs per component

52

Operation 2

milling
517
0.12
-4

Gearbox case
Bearing seats

Fine boring tool / Z = 5 / Teetheff. = 1

Ø 151
adjustable

Operation 1
HSK 100-A

Ø 85 adjustable

Ø 169

µm

25
395
Start
Operation 2

Machining plan

n=0

Operation 1
n=0
Operation 2

Requirements
Combination tool for forward and backward fine boring
and for over turning of outside diameter
Solution
Fine boring tool / Teeth = 5 / Teetheff. = 1
Cutting data
(DIN) AlSi9
Material
Cutting grade
PCD
Cutting speedm/min(Ø 85) 450
Feed rate per toothmm
0.12
ResultInserts separately replaceable

Customer benefits
Reduced machining times
Reduced tooling costs per component

53

Gearbox case
Valve plate

Face milling cutter Ø 49 mm with heavy metal shank(anti-vibration effect) / Teeth = 8

Requirements
Axial plunging into the component, face miling of the surface through the clamping devicePMr(3) >50 % - Rz 8 - Rmax 10 and axially adjustable
Solution
Face milling cutter with heavy metal shank (anti-vibration effect) / Teeth = 8
Cutting data
(DIN) GD-AlSi9Cu3
Material
Cutting grade
PCD
Cutting speed
m/min
2,700
Feed rate per toothmm
0.034 - 0.069 - 0.086
Cutting depthmm
0.6
ResultExcellent surface finish
PMr(3) 100 % - Rz 2.2 - Rmax 2.6

Customer benefits
Very high tool life quantity
Excellent surface finish quality

54

Gearshift housing
Fine boring tools

Fine machining tool with heavy metal shank and twisted guide shank /Teeth = 1

Ø 190

Ø 15.96

Requirements
Precise diameter and high coaxiality
Solution
Fine machining tool with heavy metal shank and twisted guide shank / Teeth = 1
Cutting data
(DIN) Al
Material
Cutting grade
PCD
Cutting speed
m/min
449
Feed rate per toothmm
0.056
Cutting depthmm-8ResultExcellent surface finish quality

Customer benefits
Fewer tools required for machining

55

Electric
motor

56

Electric motor
Pre-machining stator bore electric motor

Tangential inserts tool / Teeth = 4 + 4 + 4External and internal diameter machining Ø 218 mm + Ø 214 + Ø 160 mm
Basic tool body in steel and aluminium with cartridges

Light-weight
designRequirements
Strongly fluctuating allowances and machining several steps reliably
Safety cut required for bottom surface over 28 mm width
SolutionLight-weight stepped countersinking tool / Teeth = 4 + 4 + 4
Tangential inserts with underhand grip installed in the cartridge, thus very stable embedding
Cutting data
Material
AlSi10MgCu-T6
Cutting grade
PCD
Cutting speed
m/min
600 m/minFeed rate per toothmm
0.15
ResultProcess reliable machining combined with high feed rates
Long tool life thanks to a stable tool

Customer benefits
Roughing with only one tool
Reduced cycle times

57Electric motor
Semi-finish machining stator bore

Adjustable pre-machining tool / Teeth = 4 + 4 + 2 + 2 + 2
Light-weight tool concept with cartridges and PCD guide pads

Light-weight
designRequirements
Exact premachining for finishing tool
Solution
Adjustable ISO indexable inserts combined with different diameters
Light-weight construction with aluminium base body
Cutting data
Material
AlSi10MgCu-T6
Cutting grade
PCD
Cutting speed
m/min
820
Feed rate per toothmm
0.12
ResultStable machining process

Customer benefits
Pre-machining and finishing of several steps
Low cycle time thanks to multi-teeth tool58

Electric motor
Finish-machining stator bore

Multi-teeth fine boring tool / Teeth = 6 + 2 + 2 + 2
Light-weight tool concept with cartridges and PCD guide pads

Light-weight
designRequirements
Fitting Ø with high surface quality and short cycle time
Solution
6-fluted tool with mixture of inserts
Light-weight construction with aluminium base body
Cutting data
Material
AlSi10MgCu-T6
Cutting grade
PCD
Cutting speed
m/min
1,000
Feed rate per toothmm
0.18
ResultCompliance with all tolerances and surface requirements

Customer benefits
Low cycle time thanks to a high feed rate
Excellent surface finish quality

59

Pumps60

Oil pump
Pump cavity

Multi-step fine boring tool / Teeth = 4 / Teetheff. = 1

65 adjustableµm

ABS 50Ø 10.5adjustableµm

Ø 31.35
adjustableØ 41.35 ±0.05
adjustable

µm

82.5

X

R 0,2

Ø 31.35
adjustable

45°

95.6

15°

Ø 35.55 +0.05 adjustableX

10°
65 adjustable

Requirements
Combination tool, all diameters adjustable
Solution
Multi-step fine boring tool / Teeth = 4 / Teetheff. = 1
Cutting data
(DIN) GGG40
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 41.35) 197
Feed rate per toothmm
0.15
Cutting depthmm-3
ResultFlexible tool design
Inserts separately adjustable

Customer benefits
High flexibility of diameter offsets

61

Oil pump
Pump cavity

Operation 1: multi-step fine boring tool / Teeth = 3 + 5
Operation 2: step milling cutter / Teeth = 4 + 8
Operation 3: multi-step fine boring tool / Teeth = 1 + 1 / 3

Operation 1

z=3
45°

Ø 62.6 adjustablez=5
Ø 27.6 adjustable

HSK 63-A

1.2 = 1 x 45°
on finish Ø 28

84
105

Requirements
Operation 1: fine boring tool for rough machining of the pump cavity
Operation 2: step milling cutter for simultaneous milling of the sealing surfaces,
distance (dim. 49) μm-accurate adjustable
Operation 3: fine machining of both diameters with CBNSolution
Operation 1: multi-step fine boring tool / Teeth = 3 + 5
Operation 2: step milling cutter / Teeth = 4 + 8
Operation 3: multi-step fine boring tool / Teeth = 1 + 1 / 3
Cutting data
Operation 1
Operation 2(DIN) GG25
Material
Cutting grade
carbide coatedcarbide coatedCutting speedm/min(Ø 27.6) 108 (Ø 62.6) 242(Ø 23) 92 (Ø 63) 250
Feed rate per toothmm(Ø 27.6) 0.15 (Ø 62.6) 0.09 (Ø 23) 0.12 (Ø 63) 0.06
Cutting depthmm-3~2
ResultReduced machining time

Customer benefits
Low costs per component
Higher process reliability

62

Operation 3
CBN
240
0.1
0.2

Oil pump
Pump cavity

Operation 3: fine machining of both diameters with CBNOperation 2

Ø 63
z=8

Ø 23
z=4

HSK 63-A

7.8
49 adjustable

7. 8
129 adjustable
129.2 adjustable

Operation 3

Ø 27.8 z = 1
adjustableØ 63.1 H8 adjustablez=3
Ø 28 H6 adjustable
z=1

HSK 63-A

CBN

77
129

63

Oil pump
Forward and backward fine boring tool / Teeth = 7 / Teetheff. = 1µmOperation 1

Operation 2

Operation 3

EM Ø 34.8 +0,4

EM Ø 42 H8

EM Ø 62 H8

HSK 50-C

14
68
17

105
140

Ø 32

Machining plan
n=0

Operation 3

Requirements
Combination tool for 6 machining steps
All inserts adjustable
Solution
Forward and backward fine boring tool / Teeth = 7 / Teetheff. = 1
Cutting data
(DIN) AlSi9
Material
Cutting grade
PCD
Cutting speedm/min(Ø 62) 467
Feed rate per toothmm
0.12
Cutting depthmm
0.5
ResultShort processing time
Inserts can be changed separately

Customer benefits
Low costs per component

64

n=0

Operation 2

Operation 1

Start

Injection pumpMulti-step fine boring tool / Teetheff. = 2

Requirements
Multi-step machining with one tool
Solution
Multi-step fine boring tool / Teetheff. = 2
Cutting data
(DIN) ENAC-AlSi12CuNiMg
Material
Cutting grade
PCD 10Cutting speed
m/min
1,500
Feed rate per toothmm
0.13
ResultShort machining time
Very good surface quality and dimensional accuracy
Inserts can be changed separately depending on wear

Customer benefits
Cycle time reduction thanks to combination of several machining steps
Low costs per component

65

Injection pump
Flange machining

Modular designed fine boring tool
Angular position of inserts for sealing surface adjustable

129.95 -0.02 adjustableµm

108 -0.05 adjustableµm

EM Ø 36 H7
42Ø 68.2EM Ø 68 H7

HSK 63-AØ 159

relative position adjustablemicro adjustment24
130

Requirements
Combination tool for 6 machining steps, cartridges for different types of workpieces
Inserts adjustable in diameter
Solution
Modular designed fine boring tool
Angular position of inserts for sealing surface adjustable
Cutting data
(DIN) GD-AlSi12Cu
Material
Cutting grade
PCD
Cutting speedm/min(Ø 68) 641
Feed rate per toothmm
0.12
Cutting depthmm-4ResultFlexible tool design for high requirements

Customer benefits
High process reliability

66

Injection pump
Flange machining

20°

20 °

EM Ø 36,3 ±0,530°EM Ø 66,6

Micro-adjustment
allows the precise adjustment of thetool diameter directly in the machine
without using any devices, thisleads to a reduction of non-productive times in continuously running
processes e.g. mass production of
automotive components.

1 revolution = 0.02 mm in Øµm

122 -0.03 adjustable

100

PCD inserts

67

Injection pump
Axial grooving

Axial grooving tool with heavy metal shank / Teeth = 2 / Teetheff. = 1
Replaceable head designØ 26.45 adjustable39

Ø 15.95 adjustable

Requirements
Grooving tool with adjustable inserts
Solution
Axial grooving tool with heavy metal shank / Teeth = 2 / Teetheff. = 1
Replaceable head design
Cutting data
(DIN) 20MnCr5
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 21,2) 121
Feed rate per toothmm
0.08
Cutting depthmm
into solid
ResultGood chip control thanks to cutting division
Excellent surface finish

Customer benefits
High process reliability

68

Injection pump
Sealing surface, hard machining

Fine boring tool / Teeth = 1

relative position adjustableµm

Ø 15.5

HSK 63-A

63.8
129,8
adjustable

Requirements
Hard machining of the sealing surface
Angular position of inserts on tool holder adjustable
Solution
Fine boring tool / Teeth = 1
Cutting data
Material
60 - 62 HRC
Cutting grade
Cutting speed
m/min
Feed rate per toothmm
Cutting depthmm
ResultExcellent surface finish quality
Very good tool life
Regrindable CBN inserts(DIN) 20MnCr5
CBN
195
0.025
0.2

Customer benefits
Low costs per component

69

Injection pump
Cam cavity

Multi-step fine boring tool / Teeth = 7 / Teetheff. = 1 /(Ø 66.5 + Ø 63.3) Teeth = 2µm
HSK 63-AØ 13.7 H7adjustableØ 19.1 H9adjustableØ 47.1 H8 adjustableØ 66.5 h8 adjustableØ 63.3 +0.1 adjustable

µm

3°

18
85 ±0.02
101.3 ±0.02 adjustable
152.5 ±0.02

Requirements
Combination tool for 5 machining steps
Solution
Multi-step fine boring tool / Teeth = 7 / Teetheff. = 1 / (Ø 66.5 + Ø 63.3) Teeth = 2
Cutting data
(DIN) 20MnCr5
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 13.7) 37 (Ø 66.5) 180
Feed rate per toothmm(Ø 13.7) 0.15 (Ø 66.5) 0.075
Cutting depthmm(Ø 13.7) 0.5 (Ø 66.5) 0.5 - 1.5
ResultInserts separately adjustable and replaceable

Customer benefits
Low costs per component

70

Oil pump
Rotor clearance

Fine boring/grooving tool / Teeth = 2 + 2µm

Ø 64.6 adjustableØ 87.7 adjustable

ANSI-CAT 40

100

Requirements
Inside and outside diameter adjustable
Solution
Fine boring/grooving tool / Teeth = 2 + 2
Cutting data
(DIN)
Material
Cutting grade
Cutting speed
Feed rate per tooth
Cutting depth
ResultVery good tool life

m/min
mm
mm

GG25
carbide coated220
0.1~ 12, entire cutting width

Customer benefits
Low costs per component
High process reliability
Simple tool handling71

Injection pumpPre-machining connecting flange

OD turning tool,
stationary tool (turning machine) / Teeth = 2 + 2 + 1 + 1

Requirements
Reduction of cycle times
Solution
OD turning tool, stationary tool (turning machine) / Teetheff. = 2 / 1
Cutting data
(DIN) X17CrNi16 / 1.4057
Material
Cutting grade
carbide coatedCutting speed
m/min
200
Feed rate per toothmm
0.125
Cutting depthmm
4ResultFaster machining with consistent quality

Customer benefits
Reduced cycle times up to 66 %72

Stainless steel pumpMulti-step fine boring tool / Teeth = 2 + 2 + 2 + 1 + 1 + 1 + 1

Ø 86 H7 adjustablez=2
Ø 21 h7 adjustable
z=2

µm

21.5

135
adjustable

C
A
90°

270°

View B
at 155°1 x 45° adjustable
View C
at 258°33

2°D

View A
at 90°

Ø 87
z=2

258°

B

Ø 96

180°

HSK 63-A

155
°

Ø 100

µm

View D
at 332°0,7 x 30° adjustable

1 x 45° adjustable

Requirements
Combination tool, all diameters adjustable
Solution
Multi-step fine boring tool / Teeth = 2 + 2 + 2 + 1 + 1 + 1 + 1
Cutting data
(DIN) X2CrNi19-11
Material
Cutting grade
carbide coatedCutting speed
m/min
25 - 100
Feed rate per toothmm
0.025
Cutting depthmm
0.4
ResultFlexible tool design

Customer benefits
Short machining time
Low costs per component73

Various
automotive
components

74

Starter housing
Milling and overturning tool / Teeth = 8 (milling), 2 (fine boring)

12µm

Operation 1
milling

Operation 2
fine boring
HSK 63-A

Ø 19 ±0.05 adjustablez=2

Ø 63 ±0.05 adjustable
z=8

0.3

12

100 adjustable

Requirements
Milling and overturning of a stud with one tool
Face runout of the milling cutter and diameter of the fine boring tool are adjustable
Solution
Milling and overturning tool / Teeth = 8 (milling), 2 (fine boring)
Cutting data
(DIN) GDAlSi12
Material
Cutting grade
PCD
millingfine boring
Cutting speedm/min(Ø 63) 1.800 (Ø 19) 543
Feed rate per tooth
mm
0.12
0.12
Cutting depth
mm
0.8
0.8
ResultReduced machining time thanks to combination tool

Customer benefits
Low costs per component
Increased productivity

75

Camshaft
Drive slot

Gang milling cutter / Teeth = 18 / 14

µm

Ø 160

HSK 80-C

z = 14z = 18

53.5

55.5
170

Requirements
Machining of two types of camshafts with only one tool
Solution
Gang milling cutter / Teeth = 18 / 14
Cutting data
(DIN) GGG40
Material
Cutting grade
carbide coatedCutting speed
m/min
80
Feed rate per toothmm
0.06
Cutting depthmm
Teeth = 18 / 16 Teeth = 14 / 7
ResultReduced non-productive times
Reduced machining stations

Customer benefits
Increased productivity

76

Camshaft
Drive slotz = 189.8 ±0. 05 adjustablez = 146.5 ±0.1z=3

0.4 ±0.2 x 45° adjustable

15.4 ±0.1

z=6

0.6 ±0.2 x 45° adjustable

Ø 160

µm

4.6 ±0.05 adjustable77

Crankshaft
Fine boring and chamfer tool / Teeth = 1 + 1

3x carbide guide pads

µm

run out check diameter

6 0°

Ø 15.535 ±0.035
z=1Ø 21.15

Coolant exit

X
5.14
18.9
±0.03

53

25°

Ø 15.535

X±0.035128

128

Requirements
Fine boring tool with carbide guide pads for machining of the flange bore
Solution
Fine boring and chamfer tool / Teeth = 1 + 1
Cutting data
(DIN) GGG60
Material
Cutting grade
carbide coatedCutting speed
m/min
80
Feed rate per toothmm
0.12
Cutting depthmm
0.15
ResultHigh dimensional accuracy thanks to tool concept with guide pads

Customer benefits
Higher process reliability

78

HSK 63-A

FrameSpecial face milling cutter / Teeth = 8
Equipped with standard PCD inserts

HSK 63-A

Ø 63

µm

12
115 adjustable

R z 15 - 18

Requirements
Milling of the sealing surface with a defined surface roughness
All inserts axially adjustable
Solution
Special face milling cutter / Teeth = 8
Equipped with standard PCD inserts
Cutting data
(DIN) AlSi12Cu
Material
Cutting grade
PCD
Cutting speed
m/min
3560
Feed rate per toothmm
0.16
ResultHigh machining speed thanks to special insert geometry
Constant wear - all inserts set to same height

Customer benefits
Low costs per component
Increased productivity

79

Gearshift fork
Gang milling cutter (monoblock) / Teeth = 10 / Teetheff. = 5
Inserts interchangeable among each other,thus both cutting edges of the inserts can be used

All inserts adjustable (dim. 5 mm)

HSK 63-AØ 27µm

5 ±0.05 adjustable

75 adjustable

Requirements
Very unstable component, requires low cutting forces of the tool
Machining of the two ring surfaces in one cut
Solution
Gang milling cutter (monoblock) / Teeth = 10 / Teetheff. = 5
Inserts interchangeable among each other thus both cutting edges of the inserts can be used
All inserts adjustable (dim. 5 mm)
Cutting data
(DIN) C35-520 N/mm²
Material
Cutting grade
carbide coatedCutting speed
m/min
120
Feed rate per toothmm
0.1
Cutting depthmm
both sides 0.6
ResultShort machining time
Inserts usable on both sides

Customer benefits
Low costs per component

80

Axle carrier
Gang milling cutter

Large radii can be achieved
Tangential inserts with PCD cutting edges

Requirements
Milling connection taps in a single step
Solution
Gang milling cutter for double-sided milling of two taps
Cutting data
AlSi9
Material
Cutting grade
PCD
Cutting speed
m/min
1,250
Feed rate per toothmm
0.1
Cutting depthmm
3-12!
ResultProcess reliable machining of combined work steps

Customer benefit
Long tool life thanks to PCD-coated cutting inserts
Short machining times as a result of multiple operations being combined in one tool81

Steering housing
Reaming tool / Teeth = 13
Adjustment range 60 μm for diameter

5 μm per turnInterchangeable inserts• Diameter μm-accurate adjustable• Adjustment to both directions• Adjustment range 60 μm for diameter
5 μm per turn• Interchangeable inserts

Extension of
pocket seat

0,037475 max.
0,032949
0,028423
0,023897
0,01937
0,014844
0,010318
0,0057912
0,0012649-0,0032614 min.

zxy

HSK 100-A

Ø 110
z = 13µm

12adjustable

220
240

Requirements
Diameter μm-accurate adjustable in both directions
Solution
Reaming tool / Teeth = 13
Adjustment range 60 μm for diameter 5 μm per turnFreely selectable and exchangeable inserts
Cutting data
(DIN) GGG50
Material
Cutting grade
carbide coatedCutting speed
m/min
160
Feed rate per toothmm
0.2
Cutting depthmm
0.25
ResultReduced non-productive time thanks to adjustment options on the machine

Customer benefits
High process reliability
High productivity

82

Drive flange
Combination tool for the complete component contourØ 16 h6

Ø 12.4 ±0.1

Ø 18.5 H8 adjustableØ 18,5 H8 adjustable by means of eccentric pin adjustment

X20
135 adjustable
0.2 x 45°

X

R

0. 2

0.5 x 45°(20)

2 ±0.1Requirements
Combination tool for the complete component contour
Solution
Drilling and fine boring tool / Teeth = 2
Ø 18,5 H8 adjustable by means of eccentric pin adjustment
Cutting data
(DIN) Ck45
Material
Cutting grade
carbide coateddrilling
Cutting speed
m/min
71
Feed rate per toothmm
0.12
Cutting depthmm
into solid
ResultReduction of machining time thanks to combination tool

fine boring
141
0.08
3

Customer benefits
Low costs per component
Increased productivity

83

Balance shaft housing
Gang milling cutter / Teeth = 6 + 6

HSK 63-A

129 carbideØ 43 ±0.1
z=6

Ø 23

µm

Z
7.8
Ø 27 -0.03-0.05

Ø 42.4(Ø 43)

adjustable

Z
(0.3)
45°

Requirements
Machining of both ring surfaces in one cut
Solution
All inserts adjustable (dim. 5 mm)
Cutting data
(DIN) GG25
Material
Cutting grade
carbide coatedCutting speed
m/min
270
Feed rate per toothmm
0.15
Cutting depthmm
0.2
ResultShort machining time
Inserts usable on both sides

Customer benefits
Low costs per component

84

116 adjustable
155

Balance shaft housingX

HSK 63-A
A

Ø 25

µm

Ø 30.50 adjustablez eff. = 2

Circular milling cutter / Teeth = 2 + 2 + 2 + 2 + 2

A

B

C

D

B

C

D
66
90

175
198

2,1 +0,05

290

X

2
0.
R
0.3 x 45°

R

0.

2

0.3 x 45°
2.65 ±0.05

15°

A-A

30°

B-B

45°

C-C

60
°

D-D

Requirements
Circular milling cutter for the machining of grooves
Solution
Circular milling cutter / Teeth = 2 + 2 + 2 + 2 + 2
Cutting data
(DIN) Al
Material
Cutting grade
PCD
Cutting speed
m/min
490
Feed rate per toothmm
0.1
Cutting depthmm
0.5 - 1.0
ResultTool life tripled

Customer benefits
Reduced tooling costs
Reduced handling costs

85

Brake caliper
Interpolation turning tool / Teeth = 4 + 1µm

1. Step

HSK 100-A

positioning 1,25 mm ex centre

µm

1.25

µm

2.7
32

1

211.5

2. Step
3. Step

entering by interpolation to nominal diametercountersinking Ø 37 mm

2
3

Ø 39

Ø 37 adjustable
z=1

55.25

R

1
Ø 45.85 ±0.15

Requirements
Combination tool for Ø 37 mm plus seal grooves
SolutionInterpolation turning tool / Teeth = 4 + 1
Cutting data
(DIN) GGG45
Material
Cutting grade
carbide coatedCutting speed
m/min
70
Feed rate per toothmm
0.12
Cutting depthmm
0.75
ResultReduction of machining time thanks to combination toolLong tool life thanks to constant cut (interpolation turning process)Customer benefits
Low costs per component
High productivity

86

4. StepØ 26.925 adjustablez=1

Ø 35 adjustablez=1
Ø 26.625z=1
Ø 18.025 adjustable

Brake caliper

Positioning

4216

5. Step

Interpolation turning of 3 slots / grooves40(Ø 39)

Ø 51(8.25)

55.25

5
(216)

87

Timing housing
Drilling and countersinking tool with interchangeable inserts

Requirements
Machining of the complete workpiece contour with one tool
Solution
Step tool with interchangeable inserts
Cutting data
(DIN) GGG40
Material
Cutting grade
carbide coatedCutting speedm/min
52 (Ø 27.7)
Feed rate per toothmm
0.28
Cutting depthmm
into solid
ResultTool life tripled

Customer benefits
Reduced tooling costs
Reduced handling costs

88Gearbox case

8.95

10.82

1.2

Circular milling cutter with form inserts / Teeth = 4 + 4

R 0.

5
40°

R 0.25

R0

.1

R

15°

5
0.1

X

X
Ø 55.1
29°

Y

R 0.1
R 0.1

29°
Y

Requirements
Grouping of several groove machining operations
Solution
Circular milling cutters with form inserts / Teeth = 4 + 4
Cutting data
(DIN) GD-AlSi9Cu3
Material
Cutting grade
PCD
Cutting speed
m/min
1,060
Feed rate per toothmm
0.13
ResultHigh positional accuracy of the grooves and edge outlines in relation to each other
Several grooves can be produced with one tool

Customer benefits
High process reliability
High productivity

89

Balance shaft
Multi-fluted OD tool / Teeth = 3 + 1
Coolant outlet at front for 1-channel MQL system

1
Requirements
Reduction of costs per component
Solution
Multi-fluted OD tool / Teeth = 3 + 1
Cutting data
Material
Cutting grade
Cutting speed
m/min
Feed rate per toothmm
Cutting depthmm
ResultIncreased tool life by 60 %Low cutting forces
Very good chip control(DIN) C56E2
carbide coated160
0,2
6 mm in Ø

Customer benefits
Significant reduced costs per component

90

BY HOLLFELDER GÜHRING

Connecting rod
Automatically adjustable tool / Teeth = 2 + 1
SMART SETTING MOTION TOOLS conceptMachining diameter can be set µm-accurately larger and smaller
by means of a central adjusting screw

Smart
Setting
MotionTools

Requirements
Reduction of non-productive times
Solution
Automatically adjustable tool / Teeth = 2 + 1
SMART SETTING MOTION TOOLS conceptMachining diameter can be set µm-accurately larger and smaller by means of a central adjusting screw
Cutting data
(DIN) 36MnVS4Material
Cutting grade
carbide coatedCutting speed
m/min
138
Feed rate per toothmm
0.1 / 0.2
ResultHigh tool life quantity (it is re-adjusted approx. 2x per tool life)
Easy handling by readjusting the machining diameter directly in the machine spindle

Customer benefits
High productivity

91

Generalengineering

92Guide bushing
Fine boring, chamfering and circular milling tool
Teeth = 8 / Teetheff. = 1 per Ø (fine boring) / Teeth = 8 / eff. 2 per Ø (milling)

Middle part exchangeable for different types of components
All inserts adjustable
1 x 45° adjustableµm

Ø 31.7 adjustableØ 41.9 -0.05 adjustable

Operation 1
Fine boring and chamfering
Ø 42.3 adjustableµm

HSK 63-A

Operation 2
Circular milling

115 adjustable
139

10.4 ±0.05
adjustable
13.7 ±0.1

Ø 33.7 adjustable

0.7 x 45° adjustable

Requirements
Combination tool for fine boring, chamfering and milling
Solution
Fine boring, chamfering and circular milling tool / Teeth = 8 / Teetheff. = 1 je Ø (fine boring) / Teeth = 8 / Teetheff. = 2 je Ø (milling)
Middle part exchangeable for different types of components
All inserts adjustable
Cutting data
(DIN) GD-AlSi9Cu3
Material
Cutting grade
PCD
Cutting speedm/min(Ø 31.7) 750 (Ø 42.3) 1000
Feed rate per toothmm(milling) 0.065 0.13
Cutting depthmm2-3
ResultShort machining timeHigh dimensional accuracy

Customer benefits
Low costs per component
Reduced non-productive times

93Gearbox casefor angle grinders

Fine boring, chamfering and face tool / Teeth = 6 eff. 1 per Ø
All inserts adjustable
Exchangeable cartridges for different types of housingsµm

HSK 63-C
EM Ø 14,2 H6

EM Ø 23,5 ±0.05-0.003EM Ø 26 +0.007

EM Ø 52 f6

EM Ø 44

EM Ø 51µm

EM Ø 26.6 +0.2

all adjustable

6.5

25.5
211

Requirements
Combination tool for 6 machining steps
Solution
Fine boring, chamfering and face tool / Teeth = 6 eff. 1 per Ø
All inserts adjustable
Exchangeable cartridges for different types of housings
Cutting data
(DIN) GD-AlSi9Cu3
Material
Cutting grade
PCD
Cutting speed
m/min
800
Feed rate per toothmm-0.15
Cutting depthmm
0.5
ResultShort machining timeHigh dimensional accuracy

Customer benefits
Low costs per component
Reduced non-productive times

94Gearbox casefor hand drills

Drilling and fine boring tool
Inserts adjustable

Operation 1
drilling and fine boring

ABS 50Ø 14.5

Ø 20.75 ±0.05
adjustableØ 30 ±0.1 adjustableØ 15.5 adjustableµm

30 adjustable

90
120

Operation 2
circular chamfering45°

1 x 45°Requirements
Combination tool for 5 machining steps
Diameter of the chamfer and the facegroove adjustable
Solution
Drilling and fine boring tool
Inserts adjustable
Cutting data
(DIN) AlSi12
Material
Cutting grade
carbide coateddrilling and chamfering
Cutting speedm/min(Ø 14.5) 160
Feed rate per toothmm
0.15
Cutting depthmm
7.25
ResultShort machining timeHigh dimensional accuracy

fine boring and chamfering(Ø 30) 331
0.07
4.9

Customer benefits
Low costs per component
Reduced non-productive times

95Hydraulic industry
Hydraulic component

Drilling and fine boring toolØ 25 h6

Ø 13

140°

Ø 25

µm

X
115

2.5 ±0.02
45°

Ø 15.05 +0.05
adjustable

20
adjustable

12°0' ±0°10'
X

(115)

Requirements
Drilling, chamfering and fine boring in one tool
Solution
Drilling and fine boring tool
Cutting data
(DIN) Al
Material
Cutting gradeK10
drilling
374
0.38
into solid

Cutting speed
m/min
Feed rate per toothmm
Cutting depthmm
ResultShort machining timeHigh dimensional accuracy
Solid carbide drill regrindable for several times

Customer benefits
Low costs per component
Reduced non-productive times

96

fine boring
374
0.09
1.3

Hydraulic industry
Connection holes

Fine boring and chamfering tool with indexable insertsµm

Ø 16 h6µm

Ø 11.18 adjustable

PCD-form inserts with 5 steps, all diameters adjustable

12.37

30°

Ø 11.18
adjustableØ 12.92 ±0.08

Ø 13.97

Ø 18.03 ±0.08

Ø 20.57 ±0.08
adjustableØ 21.34

97

2.16
0.25 x 45°
3.43
0.25 x 45°
5.74

Requirements
Multi-step fine boring tool for hydraulic connection
Solution
Fine boring and chamfering tool with indexable inserts
PCD-form inserts with 5 steps, all diameters adjustable
Cutting data
(DIN) GDAlSi9
Material
Cutting grade
PCD
Cutting speedm/min(Ø 21.34) 700
Feed rate per toothmm
0.1
Cutting depthmm-5ResultSimple correction of diameters by means of taper screw or eccentric pin adjustment
Inserts separately replaceable

Customer benefits
Low costs per component

97

Brake component
for wind millµm

4.2 ±0.1
10.5
40
100
118

A

Ø 91 ±0.05
z=4

2
0.

R

A
R

0.2

Ø 82.4 adjustable

SK 50

adjustable

5 ±0.1100

Requirements
Multi-step circular milling cutter for machining grooves
Solution
Circular milling cutter / Teeth = 16 / Teetheff. = 4
Cutting data
(DIN) GGG40
Material
Cutting grade
carbide coatedCutting speed
m/min
95
Feed rate per toothmm
0.11
Cutting depthmm
4ResultShort machining timeHigh dimensional accuracy

Customer benefits
Low costs per component
Reduced non-productive times98Ø 89.5 adjustable
z=4

Circular milling cutter / Teeth = 16 / Teetheff. = 4

Bearing bracket
Housing

Stepped fine boring tool with clamped PCD guide pads /Teeth = 4 / Teetheff. = 1

All inserts adjustable

5x guide pads PCD

run out check diameter

5x guide pads PCD

run out check diametercompensations adapter

Ø 51 H7
z=1

HSK 63-A

Ø 61 H6
z=1

Ø 61 g6 adjustable
z=1

µm

16

5 ±0.05
75 ±0.05
230
240

3.8

Requirements
Multi-step fine boring tool
Solution
Stepped fine boring tool with clamped PCD guide pads / Teeth = 4 / Teetheff. = 1
All inserts adjustable
Cutting data
(DIN) AlSi11Cu2(Fe)Material
Cutting grade
PCD
Cutting speed
m/min
600
Feed rate per toothmm
0.1
Cutting depthmm
0.2
ResultExcellent surface finish
Simple tool handling

Customer benefits
Higher process reliability
Low costs for replacing the PCD guide pads, if necessary99Compressor housing
Put on milling cutter Ø 80 mm / Teeth = 8 + 3
Mixed assembly: semi finish inserts (Teeth = 8) andwiper inserts (Teeth = 3)

Ø 80 ±0.05

Ø 51

Ø 27 H6µm

run out check diameter
12

uneven tooth-pitch
55

adjustable

Requirements
Surface finish Rz max. 20 µm
Flatness 0.05 mm
SolutionPut on milling cutter Ø 80 mm / Teeth = 8 + 3
Mixed assembly: semi finish inserts (Teeth = 8) and wiper inserts (Teeth = 3)
Cutting data
(DIN) GG25
Material
Cutting grade
CBN
Cutting speed
m/min
1,200
Feed rate per toothmm
0.140
Cutting depthmm
0.10
ResultIncreased tool life by 300 - 400 %Customer benefits
Dramatically reduced costs per component

100Rotor shaft
Rotor for turbine

Side milling cutter Ø 350 mm / Teeth = 12 + 12
Width 5.6 mm adjustable140

Ø 350 ±0.05
z eff. = 12

Ø 32 H7µm(5)uneven tooth-pitch

5.6 ±0.1 adjustable

Requirements
Milling of the rotor grooves
Solution
Side milling cutter Ø 350 mm / Teeth = 12 + 12
Width 5.6 mm adjustable
Cutting data
(DIN) GGG50
Material
Cutting grade
carbide coatedCutting speed
m/min
80
Feed rate per toothmm
0.05
Cutting depthmm
140
ResultFinish machining of slots in one cut
Therefore dramatic shortening of processing time compared to the grinding process

Customer benefits
Dramatically reduced costs per component

101

Hydraulic industry
Connection holes valve block

Multi-step fine boring tool with adjustable inserts /Teeth = 8 / Teetheff. = 2

73 ±0.05 adjustable

6.5 ±0.05

R 0.3

15°

62.5 ±0.05

Ø 41.45 ±0.02
adjustableØ 32 h6

Ø 47 +0.1 adjustablez=1
Ø 31.6 adjustablez=2
Ø 24 adjustablez=2
Ø 13.5µm

Ø 41.3 adjustable

µm

45°

79.5 ±0.05

79.5
190

Requirements
Tool for hydraulic connection
All diameters adjustable
Solution
Multi-step fine boring tool with adjustable inserts / Teeth = 8 / Teetheff. = 2
Cutting data
(DIN) GGG50
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 47) 180
Feed rate per toothmm(Ø 47 / Ø 41) 0.1
Cutting depthmm-5ResultShort machining time
Stable machining process

Customer benefits
Low costs per component

102

5°

Hydraulic industry
Guide rail

Milling tool with fixed insert seat / Teeth = 3
Machining of different sizes with one holder
and different interchangeable inserts

5

15.79

16.5
4.8
depth of cut

6.65
depth of cut

85

82.61

9.78

70°

Requirements
Geometric shape accuracy
Mixed machining (Steel unhardened / hardened)
Faster machining
Solution
Milling tool with fixed insert seat / Teeth = 3
Cutting data
(DIN) Toolox 33
Material
Cutting grade
CBN / carbide
Cutting speedm/min
CBN 250 / carbide 140
Feed rate per toothmm
CBN 0.03 / carbide 0.03
Cutting depthmm
4.8 resp. 6.65
ResultHigher surface finish quality
Reduced tooling costs

Customer benefits
Cycle time reduction with higher surface quality
Only one tool required for different workpiece geometries
Reduced tooling costs

103

Gearbox case
Countersinking tool with guide pads / Teeth = 1 + 1

20

211

440

40

Ø 80 adjustablez=1
Ø 20 adjustable
z=1

Requirements
Manufacturing of fitting diameters
High surface finish quality
Solution
Countersinking tool with guide pads / Teeth = 1 + 1
Cutting data
(DIN) GG25
Material
Cutting grade
carbide coatedCutting speed
m/min
88
Feed rate per toothmm
0.075
Cutting depthmm
0.2
ResultVery good coaxiality despite the long distance to be bridged
Diameter can be set with micrometre precision

Customer benefits
Reduction of the number of tools
Long tool life104

Housing
Boring tool

Drilling and countersinking tool (HT 800 + 14 steps) / Teeth = 16

Ø 42
Ø 20

Requirements
Increasing the process reliability
Solution
Drilling and countersinking tool (HT 800 + 14 steps) / Teeth = 16
Cutting data
(DIN) GGG40
Material
Cutting grade
carbideCutting speed
m/min
120
Feed rate per toothmm
0.4
Cutting depthmm
into solid
ResultFaster machining time

Customer benefits
High process reliability
Longer tool life

105

Plug contact
Fine boring tool with adjustable form inserts /Teeth = 2 + 1

Ø 2.48 adjustable
z=2

Requirements
Alternative solution to a ground carbide tool
Solution
Fine boring tool with adjustable form inserts / Teeth = 2 + 1
Cutting data
(DIN) CuZn39Pb3R500
Material
Cutting grade
carbide uncoatedCutting speed
m/min
76
Feed rate per toothmm
0.065
Cutting depthmm
into solid
ResultTool life: 1,000,000 plug contactsµm-accurate adjustability of diameters

Customer benefits
No regrinding of the entire tool necessary
Reduced storage costs

106Ultrasonic water meter
Pre- and finish-machining

GA200 Vario special solution (roughing/finishing combination) /Teeth = 1 + 1

Fine boring holder

Holder for roughing

Requirements
Reduction of machining time
Solution
GA200 Vario special solution (roughing/finishing combination) / Teeth = 1 + 1
Cutting data
(DIN) CuZn35Pb2Al
Material
Cutting grade
carbide / PCD
Cutting speed
m/min
300
Feed rate per toothmm
0.06
Cutting depthmm
4ResultReduction of required tools from 2 to 1

Customer benefits
Cycle time reduction machining with consistent quality
Reduced tooling costs

107Turbocharger
housing108

Turbocharger housing
V-contour

Interpolation turning tool / Teeth = 1

Ø 182.4

6.85

16

Ø 163.6

Requirements
Machining of a V-contour despite limited space conditions
SolutionInterpolation turning tool / Teeth = 1
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
100
Feed rate per toothmm
0.1
ResultVery short machining time
Flexible and stable tool concept with cartridge
Long tool life

Customer benefits
Low costs per component

109Turbocharger housing
Pre-machining

Stepped countersinking tool
Various inserts adjustable

Requirements
Several machining steps in one tool
Solution
Stepped countersinking tool
Various inserts adjustable
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
95
Feed rate per toothmm
0.1
ResultVery short machining time thanks to maximum possible number of teeth
Thanks to the division of the chip spaces, it is possible
to combine several machining steps

Customer benefits
Lower tool costs by using ISO inserts
Reduced cycle times

110Turbocharger housing
Finish-machining

Fine boring tool / Teeth = 1 + 1
Adjustment of the diameter by fine adjustment

Smart
Setting
MotionTools

Requirements
Step tool for finishing operation
Solution
Countersinking tool / Teeth = 1 + 1
Adjustment of the diameter by means of thread wedge adjustment
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
120
Feed rate per toothmm
0.075
ResultShort machining time

Customer benefits
Lower tool costs by using ISO insertsµm accurate adjustment directly at the spindle

low machine downtime

111

Turbocharger housing
Finish-machining

Countersinking and interpolation tool in one Ø 182.4 mm
Finishing
Plane surface from 182.4 to 155.698 mm
Interpolation process

Requirements
Different machining processes in one tool
Solution
Countersinking and interpolation tool in one Ø 182.4 mm Finishing
Plane surface from 182.4 to 155.698 mm Interpolation process
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
100
Feed rate per toothmm
0.1
Result2 machining processes in one tool
Adjustment of the diameter by means of thread wedge adjustment

Customer benefits
Lower tool costs by using ISO inserts

112

Turbocharger housing
Pre-machining

Axial grooving tool / Teeth = 2 + 2
Division of the contour into two different cutting insert geometries
Compact tool concept

Requirements
Pre-machining of a complex contour
Solution
Axial grooving tool / Teeth = 2 + 2
Division of the contour into two different cutting insert geometries
Compact tool concept
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
110
Feed rate per toothmm
0.125
ResultSimple tool handling

Customer benefits
Low costs per component thanks to multi-fluted insert

113

Turbocharger housing
Finish-machining

Axial grooving tool with profile insert / Teeth = 1

Requirements
Finishing of a complex contour
Solution
Axial grooving tool with profile insert / Teeth = 1
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
100
Feed rate per toothmm
0.1
ResultVery good surface quality and dimensional accuracyµm-accurate adjustability of diameter

Customer benefits
Low costs per component

114

Turbocharger housing
Pre-machining

Axial grooving tool, adjustable diameter / Teeth = 1 + 1
Division of the contour on two different inserts
Compact tool concept

Requirements
Pre-machining of a complex contour
Solution
Axial grooving tool, adjustable diameter / Teeth = 1 + 1
Division of the contour on two different inserts
Compact tool concept
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
95
Feed rate per toothmm
0.09
ResultSimple tool handlingInserts µm-accurate adjustable

Customer benefits
Low costs per component thanks to long tool life

115

Turbocharger housing
Pre-machining

Axial grooving tool, adjustable diameter / Teeth = 1 + 1
Division of the contour into two different cutting inserts
Compact tool concept with cartridges

Requirements
Pre-machining of a complex contour
Solution
Axial grooving tool, adjustable diameter / Teeth = 1 + 1
Division of the contour into two different cutting inserts
Compact tool concept with cartridges
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
110
Feed rate per toothmm
0.15
ResultSimple tool handling

Customer benefits
Low costs per component thanks to multi-edge insert

116

Turbocharger housing
V-contour

Interpolation turning tool / Teeth = 1

Requirements
Machining of a V-contour despite limited space conditions
SolutionInterpolation turning tool / Teeth = 1
Cutting data
(DIN) GX40NiCrSiNb38-19
Material
Cutting grade
carbide coatedCutting speed
m/min
110
Feed rate per toothmm
0.15
ResultVery short machining time
Flexible and stable tool concept with cartridge
Long tool life

Customer benefits
Low costs per component

117

Aviationtechnology

118

Fuel manifold

R1

Ø 25 h6

Ø 16.8µm

Ø 6.2 ± 0.02 adjustable
z=2

Axial grooving tool / Teeth = 2

35115

Requirements
Machining of various outside diameterswith high requirements for diameter tolerance and roundness
Reduction of machining time
Solution
Axial grooving tool / Teeth = 2
Cutting data
(DIN) TiAl6V4
Material
Cutting grade
carbideCutting speed
m/min
48
Feed rate per toothmm
0.03
Feed rate per toothmm
0.25
ResultSignificantly shorter machining time due to double fluted tool
Uniform distribution of cutting forces compared to a single-fluted tool resulting in very high roundness and uniform wall thickness

Customer benefits
High process reliability

119

Aircraft wing
Side milling cutter with distribution of cut /Teeth = 10 / Teetheff. = 5

Requirements
Increase in process reliability
Reduction of delamination with so called mesh material
Solution
Side milling cutter with distribution of cut / Teeth = 10 / Teetheff = 5
Cutting data
(DIN) Composite / CFKMaterial
Cutting grade
PCD
Cutting speed
m/min
370
Feed rate per toothmm
0.08
Cutting widthmm
0ResultIncrease in tool life quantity

Customer benefits
Higher quality, therefore lower costs for re-work

120Aircraft components
Drilling and countersinking tool with interchangeable inserts /Teeth = 1

Insert diameter µm-accurate adjustable1

BY HOLLFELDER GÜHRING

Requirements
Machining of rivet holes
Burr-free transition from holes to chamfer
Solution
Drilling and countersinking tool with interchangeable inserts / Teeth = 1
Insert diameter µm-accurate adjustable
Cutting data
(DIN) CFK / titanium
Material
Cutting grade
PCD
Cutting speed
m/min
380
Feed rate per toothmm
0.11
Cutting depthmm
into solid
ResultHigh quality of chamfer or transition thanks to PCD cutting insert
High concentricity accuracy of the solid carbide drill due to use of hydraulic chuck

Customer benefits
High process reliability
Low costs per component

121Turning
tools

122

Turning tools
Camshaft regulator

Grooving tool for turning machines / Teeth = 2 / Teetheff. = 1

WM Ø 23.9 ±0.1 adjustable

Grooving inserts adjustable towards each otherØ 20 h6

WM Ø 29.1 ±0.1 adjustable

µm

4.7
3.6

85

Requirements
Narrow tolerances of the grooves to each other
Reduction of machining time
Solution
Plunging tool for turning machines / Teeth = 2 / Teetheff. = 1
Grooving inserts adjustable towards each otherCutting data
(DIN) Sind D 11 (sintered metal)
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 29.1) 220
Feed rate per toothmm
0.1
Cutting depthmm~ 4.5
ResultReduced machining time thanks to combination tool

Customer benefits
Low costs per component
Reduced non-productive times thanks to simple tool handling123Turning tools
Case

Ø 24

Grooving tool / Teeth = 1100

Ø 11.4 +0.05

30°

20

Requirements
Finish machining chamfer 30° and Ø 11.4 + 0.05
Solution
Grooving tool / Teeth = 1
Cutting data
(DIN) 9SMn28K
Material
Cutting grade
carbide coatedCutting speedm/min(Ø 11.4) 95
Feed rate per toothmm
0.12
Cutting depthmm-1ResultHigh dimensional accuracy thanks to precision-ground cutting insert

Customer benefits
High process reliability thanks to stable insert clamping

124Turning tools
Profil shaft

1.35
adjustable

Grooving tool / Teeth = 2 / Teetheff. = 1µm

adjustable

24.45 ±0.05

120

143

Ø 16

axially adjustablewith cartridge

0.1 x 45°

0.25 x 45°

0.3 x 45°

0.55 x 45°
0.25 x 45°
1.5

2

1.5

20

Requirements
Groove turning - profil recess
Recesses adjustable towards each other
Solution
Grooving tool / Teeth = 2 / Teetheff. = 1
Cutting data
(DIN) 9SMn28K
Material
Cutting grade
carbide coatedCutting speed
m/min
120
Feed rate per toothmm
0.1
Cutting depthmm2
ResultComplete machining with one tool

Customer benefits
Cycle time reduction

125Turning tools
Bearing bracket

Combi turning tool (finishing/grooving) / Teeth = 3 / Teetheff. = 1 + 1

Ø 40

Ø 24.575 adjustablez=1

Ø 27.95 adjustable
z=1
6.025

Ø 42.625
9.025

Requirements
Reduction of cycle time
Solution
Combi turning tool (finishing/grooving) / Teeth = 3 / Teetheff. = 1 + 1
Cutting data
(DIN) AlSi12Cu1(Fe) EN-AC47100 / 11SMn30 + C1,0715
Material
Cutting grade
carbide coated / uncoatedgrooving
finishing
Cutting speed
m/min
240
320
Feed rate per tooth
mm
0.12
0.1
ResultReduced machining times

Customer benefits
Saving of tool places on turret

126

Turning tools
Shaft

Holder for skiving operations / Teeth = 1

Requirements
Very high surface quality
Reduction of machining time
Solution
Holder for skiving operations / Teeth = 1
Cutting data
(DIN) steel
Material
Cutting grade
carbide coatedCutting speed
m/min
225
Feed rate per toothmm
1.5
Cutting depthmm
0.4
ResultVery fast machining time
Excellent surface finish quality

Customer benefits
Cycle time reduction
Up to 10x faster than conventional turning
Saving of one work step (grinding)127

Enquiry form
for special tools

Customer

Date

Contact person

Telephone

StreetFax

Town/post code

E-MailWorkpiece

Drawing number

Material

Hardness/tensile
strength

Machining

Into solid

Pre cast

Blind holeThrough holePre bored

Continous cut

Interrupted cut

Highly interrupted cut

OthersRequired surface finish

Ra =

Rz =

Stock

mm

FixtureStableInstableInterference

No

Yes

MC

MachineSpindleIn Radius

OthersIn diameterap =Very instable
mm

Transferline

Lathe

Turn / milling centre
Size

30

40

45

50

HSK

Size

32

40

50

63

DIN

OthersInternal coolant

max. Rpm

Power
Left-hand cutting

Non-Rotating

Face milling cutter

Groove/end milling cutter

Disc milling cutter

128

100

No

Rotating
Power

Size

Tool balanced
Necessary cutting data

Yes

80

Multi-spindle

kW

Right-hand cutting

Shank style/Form

Remarks

Boring head

Steep taper DIN

Tool

Coolant

ae =

No
vc =

Yes > Balancing grade G
m/min

f=

Internal

External

Without

Emulsion

Oil

MQL

at
mm/U

Dry

mm/teeth

1/min
mm/minEnquiry form
for HPC special milling cutter

Please complete the enquiry form and fax to: +49 (0) 911 / 64 19 22-10 or scan and send e-mail to
info@hollfelder-guehring.de. An online enquiry can be found at www.hollfelder-guehring.deCompany name/no. if available

Contact person

StreetTown/post code

Telephonee-mail address

Date

Signature

HSK-A

Ø D2

HSK-C
HSKSK

ØD

DIN 68971

BT
CAT

L1

Workpiece

Width of cut (a e)Maximum no. of teeth

Material

IC (bar)

Reduced no. of teeth

Rough milling cutter

Allowance (a p)

MQL 1 channel

Maximum tool weight

Finish milling cutter

Surface finish Rz

MQL 2 channel

129Enquiry form
for automatically adjustable tools

Customer

Date

Contact person

Telephone

StreetFax

Town/post codee-mailWorkpiece

Drawing number

Material

Hardness/tensile strength

Designation workpiece / 3D model required!

Machining

Crankshaft bearing passage

Required surface finish
Stock
MachineBalance shaft

Ra =
mm

OthersRz =in radius

in DiameterTransferline

MC

Cylinder liner

Multi-spindle machining

Machine manufacturer
Machine type
SpindleSteep taper DINSize

HSK DIN

Size

OthersWith Internal coolant

max. Rpm

Without internal coolant
Power

Retraction of the inserts required (drawbar)?

KW

Air

Yes

Emulsion

MechanicalNo
No

Hubmechanismus

Yes

Lagerung

Intermediate bearing

Counter bearing

Tool

Right-hand cutting

Left-hand cutting

Cutting data (current process)
Coolantvc =Emulsion

m/min
MQL

f=
Air (dry)Description of machining strategy (e.g., maching direction? roughing/finishing?)

130

drawing required!

mm/U

mm/teethmm/minOur innovative tooling systems are used all over the world in many areasin the metal cutting industry. Both the highly precise standard tools
which can be used flexibly as well as our customer specific innovative toolingsolutions qualify us as a reliable partner in the metal machining industry.
Thanks to many years of experience and our specific know-how
we will increase your productivity.

Challenge us with your requirements!

147 348/19004-VI-22

HOLLFELDER-GÜHRING CUTTING TOOLS
Wertachstraße 27 • 90451 Nürnberg • Germany
Telephone + 49 (0) 911 / 64 19 22-0 • Fax + 49 (0) 911 / 64 19 22-10
E-Mail: info@hollfelder-guehring.de • Internet: www.hollfelder-guehring.de