PCD - PCBNAUTOMOTIVEWHETHER IT’S COMBUSTION ENGINES OR ELECTRIC MOBILITY:
WE ARE FACING UP TO THE MARKETS OF TOMORROW. TODAY.

POWERTRAIN:ELECTRIC ENGINE HOUSING

p. 26, 28, 32, 34

BATTERY BOX
TRANSMISSION CASE

p. 24, 70, 92

OIL SUMP
PUMP HOUSINGVALVE BODY

p. 46, 88

AIR-CONDITIONING COMPRESSOR/SCROLL COMPRESSOR

p. 118TURBOCHARGER

p. 50, 116, 126

CYLINDER HEAD

p. 16-19, 40-45,
60-65, 74, 98

CYLINDER BLOCK

p. 20-32, 36, 84, 128

CRANKSHAFT

p. 76

STRUCTURAL COMPONENTS:
SHOCK ABSORBER MOUNTING

p. 120BUMPER

p. 122

MODERN MATERIALSCHASSIS AND BRAKING:
AXLE SUBFRAME/CROSS MEMBERS ANDWHEEL CARRIERS

p. 66, 110, 112

BRAKE CALIPER
WHEEL RIMS

p. 68

MASTER BRAKE CYLINDER

p. 48, 114

CONSTANT-VELOCITY JOINTS

p. 130STEERING SHAFTFRONT AND REAR AXLE HOUSINGDAMPER FORK

p. 124

To access to the technical questionnaires
for costumised PCD/PCBN tools
you can scan the QR code.

3

YOUR RELIABLE PARTNER
AROUND THE WORLDMANUFACTURER EXPERTISE
Gühring has been involved in the development and production of PCD and
PCBN-tipped tools for over 35 years. Since its establishment, this businessdivision has developed into one of the core strengths of the Swabian tool
manufacturer. As a pioneer in the production of drilling tools, Gühring has
gradually tapped into all machining types, from milling and threading toreaming and turning, and has become known for its expertise as acomplete supplier.

CUSTOMER-FOCUSED TAILORED SOLUTIONSOur headquarters in Albstadt, Germany are home to the main PCD/PCBN
plant, where we develop and produce innovative diamond tools. 95 % ofthem are custom tools that we develop together with our customers. We
take care of our products throughout the entire operating life of PCD and
PCBN custom tools and support customers from process design throughto series deployment.

SERVICE
Our service extends far beyond the production of our tools. We will offer
you support for the entire service life of your tools, if you wish. Extensive
services and after sales support such as tool management and reprocessing (re-sharpening and re-tipping) in original quality are included in
our offer. Tool supply, comprehensive logistics, a worldwide network ofservice centres: we do everything to ensure that you can use our tools
as profitably as possible.

WE ARE THERE FOR YOU
We are nearby, everywhere all over the world. On all continents, inalmost 50 countries and in over 70 locations. A close-knit network offield service employees and locations guarantees first-class supportand quick response times. You can be sure: we are also available
close to you.

PCD/PCBN DIVISION IN NUMBERS:

48

550

9

COUNTRIESEMPLOYEES AROUND THE WORLDPRODUCTION SITES

Gühring as a whole: 48 countries

Gühring as a whole: 8,000 employees

Gühring as a whole: 70 production sites

Headquarters in Albstadt-Ebingen, Germany
With development, product management, design, production and technical ﬁeld service all based at our
Albstadt site, all of our areas of expertise are united under
one roof. This creates short communication pathways
and allows us to offer a wide range of products for the
essential automotive, machine manufacture, aviation,energy, mould construction and electronics markets.

5

MEXICO¡]Ȣ ¡ȡȡȯǔf ȡ`Q¡ȰȲ

Estamos a su disposición.
к‫ی‬Е߯ࢿΟˈʏ˕ଡ͉ଢТЬ

Jesteśmy do Państwa dyspozycji.
ㇸồ䫔寁ḡ὇㛴⊈ Jsme tu pro vás.

Wearethereforyou.

WIR SIND FÜR SIE DA.

UK
CZECH

POLAND

SOUTH
KOREA

GERMANYPOLAND CZECH UK

INDIA

MEXICO

1995

CHINA

1990

SOUTH KOREA

1985

USA

GERMANY

INDIA

CHINA

2000

2006

2011 2012

2014

2016

Founding yearsof PCD/PCBN locations

OUR PCD/PCBN PRODUCTION LOCATIONSUSAMEXICOGERMANYBROOKFIELD
Guhring Inc.
sales@guhring.com
www.guhring.com

QUERÉTARO
Guhring Mexicana S.A. de C.V.
contacto@guehring.de
www.guhring.com.mx

ALBSTADT-EBINGEN
Gühring KG Werk II
info@guehring.de
www.guehring.de

ENGLANDCZECH REPUBLIC

POLAND

BIRMINGHAM
Guhring Ltd.
info@guhring.co.uk
www.guhring.co.uk

LINE-SULKOV
Gühring s.r.o.
sekretariat@guehring.de
www.guehring.cz

DĄBROWA GÓRNICZA
Gühring Sp. z.o.o.
biuro@guehring.pl
www.guehring.pl

INDIA

CHINA

SOUTH KOREABANGALORE
Guhring India Pvt. Ltd.
info@guhring.in
www.guhring.in

CHANGZHOU
Guhring Cutting Tools Co.,Ltd
info@guhringchina.com
www.guhringchina.com

DANGJIN
Gühring Korea Co. Ltd.
info@guhring.co.kr
www.guhring.co.kr

Gühring as a whole: 48 national companies and over 70 production and service centres worldwide.

PICTOGRAMSOPERATION

TOOL MATERIALSNo set-up effort.
No training required to use the tools.

PKD

Polycrystalline diamond

Low set-up effort.
Only radial/axial adjustment andSmart Setting Motion Tools. Review ofthe setting instructions recommended.

Polycrystalline cubic boron nitride

Signiﬁcant set-up effort.
Tools with guid pads and radial/axial
adjustable cutting edges. Customer training
according to the setting instructions.

Solid carbide

MATERIAL CLASSES

TOOL TYPES

Standard tool
Available from stock withstandard dimensions.

Custom tool
Design and production
customised to machining type.

N

P

K

Aluminium,
other nonferrous metals

Steel, highalloyed steel

Types of castiron such as
grey cast iron
(GG25)

H
Hardened steel,cast steel

NUMBER OF CUTTING EDGES

1
Number of main cutting edges

COOLINGSHANK FORM

HA
Wet
machiningDrymachining

Minimum quantity
lubrication

HB

HSK-A HSK-C

to DIN 6535

ICONS FOR STANDARD PCD MILLING CUTTER RANGE
Type:

Application:

Cutting edge form:

FinishingFeed:lateral feed

WN

Corner chamfer

Number of cutting edges:

Standard:

4°

PF1000 PF3000 PF3000
G
G

Roughing

Helix angle:

Rake angle:

to Gühring
Standard

HSK-E

TABLE OF CONTENTS

1

2
3

4

REAMING

p. 10•

PCD and PCBN ﬁne boring tools

p. 14

•

PCD reamers with ISO indexable inserts

p. 30

•

PCD reamers with brazed cutting edges

p. 38

DRILLING

p. 54•

PCD drills

p. 58

•

Solid carbide drills

p. 72

MILLING

p. 78•

PCD face and corner milling cutters

p. 82

•

PCD slot drills

p. 104•

PCD contour milling cuttersp. 108TECHNICAL SECTION
p. 134

9

REAMING

REAMING

1 REAMING•

PCD and PCBN ﬁne boring tools

p. 14

•

PCD reamers with ISO indexable inserts

p. 30

•

PCD reamers with brazed cutting edges

p. 38

11

REAMING

REAMINGPCD AND PCBN FINE BORING TOOLS
Gühring ﬁne boring tools are the perfect solution wherever very high diameter tolerances, surface ﬁnishes
and shape and position tolerances are required. When conventional tool concepts reach their limits,
our tools achieve tolerances up to IT 5.
Smart Setting Motion Tools (p. 20-23)
Automatically adjustable tools or so-called Motion Tools have cutting edges that can be folded in andout via an integrated mechanism. This prevents retraction marks. An adjustment mechanism enables
the cutting edges to be adjusted in the machine within seconds.
Weight-optimised PCD ﬁne boring tools (p. 24-29)
Weight-optimised tools are used during the machining of transmission components, for example.
These improve the precision, tilting moment and durability of the machining process and the tool.

PCD REAMERS WITH ISO INDEXABLE INSERTS
Tools with exchangeable ISO elements are used due to the insert seat that is produced withhigh precision for drilling, reaming, milling, pre-machining and ﬁnishing.
A signiﬁcant advantage of this is the cost savings for tool reprocessing. The cutting inserts can beexchanged directly on site by the customer. This also results in reduced costs per component.
Adjustable short clamping holders guarantee high precision and ﬂexibility. In addition to our extensive
range of ISO inserts, our customers value our tried-and-tested custom solutions that are individuallydesigned according to user requirements.

i

You can ﬁnd our comprehensive standard range of ISO indexable inserts in the product brochure of the same name.

PCD REAMERS WITH BRAZED CUTTING EDGES
Using a highly modern production process, it is possible to manufacture brazed PCD reamers with aconcentricity of < 0.005 mm and a diameter tolerance of up to IT 6.
As a pioneer in multi-ﬂuted PCD reamers, Gühring beneﬁts from its many years of manufacturingexpertise. The six-ﬂuted PCD reamers are the ideal combination of precision and productivity.

REAMING

Maximum process reliability
Optimum diameter, shape andposition tolerances
Tolerances: from IT 5

Maximum cost efficiency
Using PCD and PCBN-tipped
ISO indexable inserts
Tolerances: from IT 7

High precision andeasy operation
Tolerances: from IT 6

13

REAMING

REAMING

PCD AND PCBNFINE BORING TOOLS

15

AUTOMOTIVE / REAMING / PCD AND PCBN FINE BORING TOOLSREAMINGCYLINDER HEAD – CAMSHAFT BEARING PASSAGE

PCD PILOT BORING TOOL AND
PCD FINE BORING TOOL
When machining the camshaft bearing passage, there are particularly high requirements for the
shape and position tolerance (cylindricity, circularity, coaxiality). The position accuracy of theﬁrst web needs to be transferred to all other webs in order to ensure parallelism and coaxiality.
High surface ﬁnishes also need to be maintained. For this Gühring provides a coordinated,
two-stage machining concept involving a pilot boring tool and a ﬁne boring tool mounted on
guide pads to ﬁnish the bore.

1

Step 1:
Pilot boring the 1st bearing web
and bearing bore ﬁnishing2

Step 2:Inserting into the pilot
bore and ﬁnishing
bearing webs 1 to 4

APPLICATION EXAMPLE
STEP 1
Pilot boring

STEP 2FinishingMaterial

AlSi9

AlSi9

Geometry (Ø in mm)

22.70 / 31.70 / 32.00

22.70 / 23.011

vc (m/min)

321

253

Feed (mm/rev)

0.1

0.1

Speed (rpm)

4,500

3,500

Coaxiality (μm)-

< 30
(entry bore for web 4)

Circularity (μm)-

< 3 (web 1-4)

Cylindricity (μm)-

< 10 (web 1-4)

Surface ﬁnish (μm)-

Rz < 3.2

1

Step 1:
PCD pilot boring tool

REAMING

HSK-A

PCD guide pads ensure
the straightness andcircularity of the bore.

ISO indexable insert,
PCD-tipped, shape C
Order no. 7666 62.020

1
Pilot boring the ﬁrst web
with PCD pilot boring tool
to Ø 22.7 mm.

μm-accurate adjustment for pilot boring andﬁnishing diameter thanks to axial and radial ﬁne
adjustment of the cutting edges on both tools.

1

insert cutter for PCD
ﬁne boring tools
Order no. 6790 75.020

Adjustable PCD
cutting edges forﬁnishing toØ 23.011 mm
and tolerance IT 6.

PCD guide pads ensure the straightness and circularityof the bore.

Thanks to the solid carbide
shank, Gühring achieves
maximum rigidity and thetightest shape and position
tolerances up to a length of
600 mm.

μm-ACCURATE PRECISION
THROUGH ALL WEBS
The two-stage machining concept of the pilot boring tool andﬁne boring tool ensures precise position accuracy of the pilot bore in theﬁrst web and then optimum guidance of the ﬁne boring tool through all
further webs. The tools can be coordinated to one another with
μm-accurate precision thanks to the ﬁne adjustment of
the cutting edges. As a result, a coaxiality of < 0.03 mm
can be achieved from the bearing bore to the last bearing web.

N

2

PKD

Step 2:Finishing
the bearing webs

17

AUTOMOTIVE / REAMING / PCD AND PCBN FINE BORING TOOLSREAMINGCYLINDER HEAD – VALVE GUIDE AND VALVE SEATPCBN FINE BORING TOOLS
Valve seat and valve guide machining is the most cost-intensive machining task on the cylinder head.
The valves control the load cycle by opening and closing the air inlet and exhaust outlet ducts.
For optimum sealing of the valve disc to the valve seat ring, tight shape and position tolerances
must be adhered to. Abrasive material also ensures a high wear factor. The tool costs are therefore
generally very high, during main times as well as downtimes. Gühring's solution guarantees
maximum productivity and cost efficiency with a machining concept involving high-power tools
with PCBN ISO indexable inserts and solid carbide reamer with concentricity ﬁne adjustment.

1

Step 1:Pre-machining
Parent metal bore

2

Step 2:Finishing
Parent metal bore

3

Step 3:Pre-machining
Valve seat and valve guide pilot boring

4

Step 4:
Finishing
Valve seat and valve guide

APPLICATION EXAMPLE
Valve seat(machining 3 angles)

Valve guide

Material

Sintered metal

Sintered metal

Geometry (Ø in mm)

22.40

6.00

vc (m/min)

120

60

Speed (rpm)

1,700

3,185

vf (mm/min)

204

956

Circularity (μm)<6<6Cylindricity (μm)-<8Seal tightness (cc/min)

< 120

-

Coaxiality (mm)< 0.03-

Step 3:pre-machining
valve guide and valve seat

integrated hydraulic expansion chuck for
optimum pilot boring tool concentricity
and easy tool change

unit with integrated ﬁne adjustment

1

precision-ground, triangular
PCBN or solid carbide
ISO indexable insert

exchangeable solid carbide pilot
reamer with concentricity ﬁne
adjustment for pilot boring in a
precise position

RAPID CHANGE
The machining concept involving the pilot boring and ﬁne boring
tool with interchangeable, precision-ground ISO indexable
inserts and ﬁne-adjustable solid carbide reamer signiﬁcantly
reduces tool costs. The 6-ﬂuted machining in the valve guidemeans that higher machining parameters can be achieved,
which reduces the cycle time. Downtimes are reduced thanks
to the Smart Setting adjustment unit.

P

H

Thanks to the 6-ﬂuted solid
carbide reamer, high cutting
parameters can be achieved in
the valve guide while adhering
to tight tolerances.

ISO full-face PCBN indexable insert,
shape T, order no. 7738 61.020
Triangular T-insert: Only one cutting edge
is in use; the remaining cutting edges areprotected within the tool.

i

You can ﬁnd our comprehensive standard
range of ISO indexable inserts in the
product brochure of the same name.

Smart Setting System GP 300 with separate
indexable insert clamp features integrated
ﬁne adjustment for μm-accurate and quick
conﬁguration of the precision-ground PCBN
cutting edges. Due to the separate tensioningof the indexable insert and clamping holder,
there is no need to repeat clamping holder
conﬁguration when changing an insert.

4

Step 4:
Finishingvalve seat and valve guide

REAMING3
HSK-A

AUTOMOTIVE / REAMING / PCD AND PCBN FINE BORING TOOLSREAMINGCYLINDER BLOCK – CYLINDER BORE

SMART SETTING MOTION TOOL
In order to reduce fuel consumption and ensure that the vehicle is optimally powered, the friction
between the cylinder and piston must be kept as low as possible. This means extremely stringent
requirements in terms of dimensional, position, shape and surface tolerances. A surface roughnessof Rz 15-30 μm is required prior to the honing process; retraction marks in the bore must be avoided.
Until now, this was only achievable with complex tool concepts or time-consuming processes.
Automatically adjustable SMART SETTING MOTION TOOLS from Hollfelder-Gühring are analternative solution.

APPLICATION EXAMPLE
Finishing with Smart Setting Motion Tool
Material

GG25

Geometry (Ø in mm)

86.00 mmvc (m/min)

750

Feed (mm/rev)

1,395

Speed (rpm)

2,795

Coaxiality (μm)

< 10

Circularity (μm)

< 10Angularity (μm)

< 10Ø tolerance

up to IT 6

SMART SETTING MOTION TOOLS achieve high dimensional, shape andposition tolerances due to their pronounced precision. Surface roughnessesof Ra 1.6-3.2 μm are easy to achieve. Retraction marks can, for example,
be prevented with eccentric extension. Alternatively, the tools can also beequipped with collapsible cutting edges. This is controlled by a mechanicalpull rod or compressed air. The central adjustment unit means that you canconﬁgure all ﬁnishing cutting edges simultaneously within a few seconds
directly in the machine.

K

Smart Setting Motion Tool
with integrated μm-accurate
and quick ﬁne adjustment.
Adjustments can be performed
directly in the machine using
a simple adjustment spindle,
meaning downtimes are reduced.

Distinctly uneven spacing of
the cutting edges for eccentric
retraction and extension in and outof the bore to prevent retraction
marks.

Specially adapted cutting
geometries ensure a deﬁned
surface ﬁnish. The tool is equippedwith individual PCBN grades
depending on the material to bemachined.

HSK-C

i

You can ﬁnd our comprehensive standard
range of ISO indexable inserts in the
product brochure of the same name.

21
21

REAMINGNO RETRACTION MARKS,
FINE ADJUSTMENT IN SECONDSAUTOMOTIVE / REAMING / PCD AND PCBN FINE BORING TOOLSREAMINGCYLINDER BLOCK – CRANKSHAFT BEARING PASSAGE

SMART SETTING MOTION TOOL
Higher than average requirements for shape and position tolerances for the bores are also a big
factor when machining the crankshaft bearing passage. Complicated presetting processes result in
considerable set-up time and downtimes, which need to be reduced. Using the SMART SETTING
MOTION TOOL technology, components can be machined on conventional machining stations.
Special machines with a lifting mechanism to raise the component are not required.

APPLICATION EXAMPLE
STEP 1Pre-machining

STEP 2FinishingMaterial

GG25 / AlGG25 / Al

Geometry (Ø in mm)

71.50

71.50

vc (m/min)

185

250

Feed (mm/min)

124

111

Speed (rpm)

824

1,113

Coaxiality (μm)

-

< 15

Circularity (μm)

-

< 15

REAMING

HSK-A

SMART SETTING MOTION TOOL
The line boring bar with counter bearing has integrated ﬁne
adjustment and a folding mechanism for collapsing all cutting edges.
This means that the component to be machined does not require a
lifting mechanism. Aids for presetting, such as V-gauges, are also not
required. No tool changes are required for re-adjustment, which also
prevents any dimensional ﬂuctuations.

Clamp mount available
with eccentric adjustment
and ISO inserts.

Folding mechanism withhydraulic or mechanicalactivation for collapsing the
cutting edges, meaning
it can be used on CNC
machines.

0

The cutting edges can be conﬁgured
within a μm range in seconds using
a special adjustment key inside themachine.

Bearing web 2>II< = 0.002 mm im Øi

You can ﬁnd our comprehensive standard
range of ISO indexable inserts in the
product brochure of the same name.

The alternative to this is an integrated
setting mechanism that can be used toperform ﬁne adjustment for all ﬁnish cuttingedges on the tool. Diameter adjustment ispossible in both directions +/-.

23

AUTOMOTIVE / REAMING / PCD AND PCBN FINE BORING TOOLSREAMING

TRANSMISSION CASE – MAIN DRIVE SHAFT BORE

WEIGHT-OPTIMISEDPCD FINE BORING TOOL
The ﬁnishing of so-called main drive shaft bores in the machining of transmission case requires tool
diameters of up to 300 mm. These tools have a very high dead weight of more than 20 kg, whichleads to a high load on the machine spindle and a high tilting moment. If lighter tools are used whenmachining the main drive shaft bore, this has a positive effect on the precision of the machining andthe service life of the machine spindle.

1

Step 1:Pre-machining
PCD circular milling cutter

2

Step 2:Semi-finishing
PCD milling cutter

3

24

Step 3:Finishingwith the weight-optimised
PCD ﬁne boring tool withaluminium base bodyDue to the use of a special aluminium, this PCD ﬁne boring tool canreach a maximum weight of 14 kg at Ø 300 mm, which has a positiveeffect on the precision of the machining. In addition, the set-up costs areminimised thanks to the pre-set PCD cutting edges and guide pads thatare ground within tolerances.

N

PKD

Minimised set-up
costs thanks to thepre-set PCD cuttingedges and guide pads
that are ground withintolerances.

All cutting edges canalso be re-adjusted
in a radial and axial
direction to maximise
service life.

Sloping PCD guidepads for optimum
guiding behaviour ininterrupted cutting.

Screw-ﬁtted, exchangeable clamping
holders make it possible to re-tip the tool
quickly, easily and without thermal stresson the base body. This has a positiveeffect on the service life of the tool.

HSK-A

3

Step 3:Finishing

25

REAMING

LIGHTWEIGHTFOR LOW TILTING MOMENTREAMING

REAMING

E-MOBILITY
Sustainability, emission-free engines and less relianceon fossil fuels: the mobility of our future is changing.
E-mobility is a central topic of the energy revolution,
making electric vehicles an important aspect of thetransport revolution. Electric engines are therefore
being used in hybrid vehicles as well as purely electricvehicles.
The housing for electrical engine components is
produced using aluminium alloys and is machinedusing Gühring PCD tools. Since the start of theelectriﬁcation of the automotive industry, we haveunderstood the pressing issues for our customers andhave provided tried-and-tested tool concepts.

AUTOMOTIVE / REAMING / PCD AND PCBN FINE BORING TOOLSREAMING

ELECTRIC ENGINE HOUSING – STATOR BORE

WEIGHT-OPTIMISEDPCD FINE BORING TOOL
In order to ensure precise machining results when machining bores with large diameters of up
to IT 6 tolerance and tight shape and position tolerances, the tool must be as light as possible
and also temperature-resistant depending on the machining environment. Gühring provides alightweight tool made from titanium to meet these speciﬁc requirements.

APPLICATION EXAMPLE
Finishing with weight-optimised
PCD ﬁne boring tool
Material

AlSi10Mg

Geometry (Ø in mm)

309.00Tool weight (kg)

12.5

vc (m/min)

1,164

Feed (mm/rev)

0.3

Speed (rpm)

1,200

REAMING

LIGHTWEIGHT AND
THERMALLY STABLE
The ﬁne boring tool made from a titanium alloy is extremely lightand more resistant to temperature changes than other materials.
FEM simulations have enabled us to achieve a topologically
optimised geometry. The struts ensure that the tool is as rigid as
possible, which increases process reliability. The reduced tool
weight also reduces the load on the machine spindle.

N

PKD

PCD guide pads andadjustable PCD cuttingedges ensure precise
machining results.

lightweight tool withtitanium alloy base bodyfor maximum precision andthermal stability

HSK-A

topology-optimised geometry
Titanium alloy holder – HSK steel: rigidity analysis

0.0075 Max
0.00650.00560.00470.00380.00280.00190.00098
5.5e-5-0.00087 Min

In order to achieve maximum
rigidity with the lowest
possible material usage,
Gühring's own research anddevelopment department
performs FEM simulations,which are incorporated into
the design.

without optimisation

optimised geometry

29

REAMING

REAMING

PCD REAMERS WITH
ISO INDEXABLE INSERTS

31

AUTOMOTIVE / REAMING / PCD REAMERS WITH ISO INDEXABLE INSERTS

REAMING

ELECTRIC ENGINE – BEARING SEAT ON THE TRANSMISSION AND ENGINE SIDEPCD FINE BORING TOOLS WITH
ISO INDEXABLE INSERTS
Shape and position tolerances play a prominent role in the machining of the bearing seat in theelectric engine. The tool costs are therefore generally very high, during main times as well as
downtimes. Reamers with PCD-tipped ISO indexable inserts provide a cost-effective solution
in this case.

Step 2:Fine machining
Bearing seat, output

2

Engine-side view

32

1

Step 1:Fine machining
Bearing bore

Step 1:Fine machining
Bearing bore
REAMING1

module adapter for the bestmachining results

HSK-A

Constructional pre-balancing
via the chip spaces provides
additional stability.

COST-EFFECTIVE PRECISION
1

Gühring is offering a wide range of PCD tools with ISO elements for
precise machining with tight tolerances. A signiﬁcant advantage of ISO
elements is the reduced costs for reprocessing. Tool stock can be
reduced in comparison to brazed PCD tools because re-tipping can be
performed by the end user in very short time.

N

PKD

guide pads for the tightest shapeand position tolerances

2

Step 2:Fine machining
Bearing seat, output

1
Fine adjustment unit
enables axial and dual radial
adjustment for the bestmachining results.

In order to prevent the guide pads from deforming behind thecutting edge due to the clamping screw, the geometry has
been pre-emptively optimised using FE simulation.

without optimisationi

optimised geometry

You can ﬁnd our comprehensive standard
range of ISO indexable inserts in the
product brochure of the same name.

0.057 Max
0.051
0.044
0.038
0.032
0.025
0.019
0.013
0.0063
0 Min

HSK-A

33

AUTOMOTIVE / REAMING / PCD REAMERS WITH ISO INDEXABLE INSERTS

REAMING

ELECTRIC ENGINE – BEARING SEAT ON THE ENGINE SIDE

PCD HOOK TOOL WITH
ISO INDEXABLE INSERTS
The bores are ideally only machined from one side when machining the housing in the electricengine due to the very tight shape and position tolerances. This results in laborious retraction
motions in order to prevent position errors that can arise from the operation of the machine axes.

Machining the contact surface
and chamfer on the bearing seat(engine side) pulling backwards
with the PCD hook tool34

REAMING

PROCESS ELIMINATED
Hook tools are used in this instance to machine opposite bores
eccentrically and with a backwards pulling motion. PCD reamers
with exchangeable ISO elements guarantee precise machining
thanks to the integrated adjustment mechanisms. The cutting
inserts can be exchanged directly on site by the customer.

N

PKD

PCD cutting edge forchamfer machining

1

ISO indexable insert for eccentricmachining of the bearing bore in
the electric housing
ISO indexable insert, PCD-tipped,shape C, simple geometry
Order no. 7670 93.020

Constructional pre-balancing
via heavy metal element: Thebalancing piece is designed using
the latest design software, taking
into account the tool material
and tool geometry. This makes
it possible to achieve balance
quality grades of up to G2.5.

HSK-A

35

AUTOMOTIVE / REAMING / PCD REAMERS WITH ISO INDEXABLE INSERTS

REAMINGCYLINDER BLOCK – MECHANICAL ROUGHENING

PCD ROUGHENING TOOL
When car manufacturers thermally coat the aluminium surfaces of the cylinder bore instead of
installing conventional cast iron liners to create a cylinder bore surface, engines can be madelighter and more efficient. Gühring has developed a roughening tool system for this process which
provides an optimum adhesive layer and also makes the production of these engine components
more cost-effective.

APPLICATION EXAMPLE
Mechanical roughening
Material

Aluminium

Geometry (Ø in mm)

84.00-104.00

vc (m/min)

600

Feed (mm/rev)

0.25 – 0.4

Speed (rpm)1,800 – 2,500

Achieved adhesive pull strength (MPa)> 40Service life

> 1,500 bores

REAMING

HSK-A

Using a thread cycle, theroughening cutting edge
creates a dovetail proﬁleto which the thermal layer
can cling.

1

Gühring offers geometries thathave been tried and tested over thelong term for the different methodsof thermal spraying of cylinder
bore surfaces. For example, adiamond roller is used to roughen
cast iron cylinder bore surfaces,
as is primarily the case in thecommercial vehicle sector.

COATING INSTEAD OF LINERS
Gühring has developed a PCD tool to roughen the cylinder bore
surfaces before coating them using a patented dovetail proﬁle. In
series production, the Gühring insert guarantees optimum surface
roughness for the subsequent thermal coating.

K

N

PKD

37

REAMING

REAMING

PCD REAMERS WITH
BRAZED CUTTING EDGES

39

AUTOMOTIVE / REAMING / PCD REAMERS WITH BRAZED CUTTING EDGESREAMINGCYLINDER HEAD – PARENT METAL BORE

PCD STEP REAMERS
The blind bore, into which the valve guide is pressed, and the base seat, into which the valve ringis pressed, have tight shape and position tolerances. These tight tolerances are necessary so theinlet and outlet valves, which are controlled by the camshaft, can run smoothly when opening
and closing. The tight shape and position tolerance of the blind bore to the base seat can be
guaranteed by using a monoblock and multi-ﬂuted reamer.

APPLICATION EXAMPLE
FinishingBase seat and blind bore
Material

AlSi7

Geometry (Ø in mm)

9.00 / 27.00

vc (m/min)

337 / 960

Feed (mm/rev)

0.48

Speed (rpm)11,308Circularity (μm)<8

REAMING

The multi-ﬂuted PCD
reamer with 6 unevenly
spaced cutting edges
can be operated withhigh cutting parameters.

PRECISIONWITHOUT THE SET-UP EFFORTThe combination of base seat and blind bore machining in amonoblock tool guarantees maximum precision. The tool is delivered
ground to size so there is no set-up effort required and downtimes are
reduced. A concentricity of < 0.005 mm can be produced withmulti-ﬂuted and multi-step PCD reamers by using continuous
inprocess measuring during the grinding operation.

N

PKD

The parent metal bore ismachined with 6 cuttingedges.

Maximum precision thanks to
the monoblock, shrink-ﬁt solid
carbide base body, which
is used to grind blind bore
and basic seat machining
diameters to size duringassembly.

ﬁne balancing thread for optimum
balance quality grades of up to G 2.5

HSK-A

41

AUTOMOTIVE / REAMING / PCD REAMERS WITH BRAZED CUTTING EDGESREAMINGCYLINDER HEAD – HYDRAULIC VALVE PLAY COMPENSATOR

PCD REAMER
The hydraulic valve play compensator reduces the maintenance outlay for the engine as valve
readjustment is not required. For precise valve play compensation, diameter tolerances of IT 7 arerequired on the component. The transverse oil gallery bore is also particularly challenging. Whenmachining using conventional tools, a burr will occur in interrupted cutting, which is pressed into theoil duct. This negatively affects the machining result and the cycle time. The burr has to be removed
in an additional work process.

1

Step 1:Pre-machining
spiral-ﬂuted PCD drill

2

APPLICATION EXAMPLE
Finishing – hydraulic valve play compensator
Material

AlSi9

Geometry (Ø in mm)

12.00

vc (m/min)

452

Feed (mm/rev)

0.48

Speed (rpm)12,000Circularity (μm)<6

Roughness (μm)

< 3.2

Ø tolerance≤ IT 7

Step 2:Finishing
PCD reamer

REAMING

multi-ﬂuted brazed PCD reamer (Z=6) for
maximum precision and cutting parameters

Distinctly uneven spacing of the cutting edges ensures thatthe tool is optimally guided, even in interrupted cutting. Thismeans that a circularity of < 6 μm can be achieved on thecomponent.

monoblock manufactured PCD
reamer with IT 7 tolerance

Extremely sharp PCD cuttingedges reliably shear off thematerial, preventing burr
formation in the direction of theoil gallery bore.

HSK-A

2

Step 2:Finishing
PCD reamer

BURR-FREE OIL GALLERY BORE
To prevent burr formation in the direction of the oil gallery bore,
the PCD reamer for machining the hydraulic valve compensatoris equipped with very sharp PCD cutting edges. The spiral-ﬂuted
tool design in the pre-machining process as well as the uneven
spacing of the cutting edges in the ﬁnishing process guarantee thebest machining results.

N

PKD

43

AUTOMOTIVE / REAMING / PCD REAMERS WITH BRAZED CUTTING EDGESREAMINGCYLINDER HEAD – INJECTOR BORE

PCD STEP REAMER
Multi-step machining with tight diameter tolerances up to IT 6, large drilling depths and the low
angles to be machined make injector bore machining a difficult task. Two to three coordinated tools
are used depending on the component geometry and tolerances. Ensuring perfect dimension
coordination in the pre-machining and ﬁnishing process is fundamental.

44

1

Step 1:
Pilot boring
PCD step drill

2

Step 2:Pre-drilling
PCD semi-ﬁnish
step drill

3

Step 3:Finishing
PCD step reamer

REAMING

COORDINATED CONCEPTThe machining concept involving three PCD step tools
makes the injector bore machining process μm-accurate
and reliable. Perfect measurement coordination minimises
vibration and improves chip evacuation.

N

PKD

brazed PCD reamer asmonoblock variant

solid carbide holder for
maximum rigidity
Due to the fact that we produce
our own carbide, the cooling duct
position can be adapted to thetool requirements. This meansthat maximum rigidity and processreliability is achieved despite
limited wall thickness and stepincrements.

HSK-A

3

Step 3:Finishing
PCD step reamer

45
45

AUTOMOTIVE / REAMING / PCD REAMERS WITH BRAZED CUTTING EDGESREAMINGVALVE BODY – PISTON BORE

PCD REAMERAs the control centre of an automatic transmission, this is where the commands from the control
computer are precisely executed and where the transmission components are activated. This precision
is reﬂected in the machining of the valve body. Tolerances up to IT 6 with up to ﬁve step diameters on
one tool are required. Coordinating concentricity and diameter tolerances across so many machining
levels is a very demanding task in tool production. The special requirements with regard to cylindricity,
circularity, position and very good surface ﬁnishes demand a high level of expertise, which Gühring
can offer as a pioneer in the production of multi-step PCD reamers.

Step 1:
Pilot boring
PCD reamer (Z=2)

1

Step 2:Pre-machining
PCD reamer (Z=4)

2

3Step 3:Finishing
PCD reamer (Z=6)

CYCLE TIME COMPARISON
Finishing with
PCD reamer Z=1

Finishing withmulti-ﬂuted PCD reamer Z=6

Number of cutting edges

16

Geometry (Ø in mm)

12.00

12.00

vc (m/min)

170

170

fz (mm/z)

0.15

0.08

fu (mm/rev)

0.15

0.48

Speed (rpm)

4,500

4,500

Machining path (mm)85

85

Machining time (sec)

7.56

2.36

Step 3:Finishing
PCD reamer
REAMING3

HSK-A

It is possible to level wobble errors
using the adjustable shrink ﬁt chuck.

With six cutting edges, circularities of < 6 μm
can be reliably implemented.
Our self-produced carbide enables optimum
positioning of the cooling ducts despite thestep increments, therefore ensuring maximum
rigidity and wall thickness.
Thanks to the omitted guidepads, cooling lubricant withoil content from 7 % canbe used. This reduces themaintenance costs.

CYCLE TIME REDUCED BY 70 %With six cutting edges per diameter, this PCD step reamer
machines signiﬁcantly faster than tools with one cutting edge.
The cycle time can be reduced by up to 70 %. The monoblock
version is provided ground to tolerance, which also saves set-up
effort. This makes tolerances of up to IT 6 andsurfaces with < R z 3.2 μm possible.

N

PKD

47

AUTOMOTIVE / REAMING / PCD REAMERS WITH BRAZED CUTTING EDGESREAMINGMASTER BRAKE CYLINDER – PRESSURE PISTON BORE

PCD REAMER
The very high quantities in brake cylinder production often necessitate multi-spindle machining.
Every tenth of a percent counts – the cycle time must be kept to an absolute minimum.
It is therefore important to combine machining processes and to cover large drilling depths
with maximum cutting parameters during ﬁnishing work.

1

Step 1:
Piston bore pilot boring
Outer contour ﬁnishing, PCD
combination tool (Z=2, Z=4)2

48

Step 2:
Piston bore finishing
PCD reamer (Z=6)

REAMING

MORE CUTTING EDGES,LESS CYCLE TIME
The multi-ﬂuted tool concept for the piston bore achieves thebest quality in a short cycle time. Maximum cutting values
ensure an adequate main time; downtimes can also be
reduced by brazed cutting edges without any set-up effort.

N

PKD

Multi-ﬂuted brazed
machining concept
reduces cycle time andset-up effort.

optimum circularities of < 6 μm
thanks to six-ﬂuted geometry

HSK-A

2

Step 2:Finishingpiston bore

49

AUTOMOTIVE / REAMING / PCD REAMERS WITH BRAZED CUTTING EDGESREAMINGTURBINE WHEEL – HUB BORE

HEAD-TIPPED PCD REAMER
The turbine in the turbine housing of a turbocharger is driven by engine exhaust gases and drives
the compressor wheel via a shaft. The compressor increases the air ﬂow and executes the suction
work of the pistons. In this process, precise ﬂow and low energy loss between the driven turbine
wheel and the compressor wheel are essential. Multi-ﬂuted reamers are used here. But the smaller
the tool diameter, the harder it is to tip the tool with individual PCD cutting edges while adheringto the extreme tolerance requirements. This is why head-tipped PCD reamers are used when you
need to machine small diameters between 3 and 6 mm.

Hub bore:
PCD reamer up to Ø 3.00-7.00 mm

50

REAMING

CLEVER HEADSWith the head-tipped PCD reamers from Gühring, even small
diameters can be implemented with up to six cutting edges. In
the design of the tools, larger freedom results from the cylindrical
headpiece, which would not be achievable with individual cuttingedges. The head tipping allows various machining tasks to be
performed with precision and speed, such as the bearing bore in
the turbine wheel or the machining of the valve guides.

K

N

PKD

Head tipping enables complex
face geometries to be executedfor reaming and drilling.

Up to six cooling ducts arranged
circumferentially, which arevariably available for blind holes
and through holes.

HA

Solid carbide holder for
maximum rigidity

Also suitable for valve guide machining.

51

REAMING

REAMING

SLM chip-evacuation element
for machining depths up to 3xD, Ø > 14 mm
Additive-manufactured PCD tool; 360° closed chip
space, high degree of freedom in the design as well as
optimised cooling ducts and maximum rigidity.

CHIP-EVACUATION ELEMENTS
BY GÜHRING
Brazed or screwed-on solid carbide chip-evacuation elementsroll up the chip in a deﬁned manner and remove it reliably, evenwith deep bores or high material evacuation.
Additive-manufactured heads are also now part of theestablished range of PCD tools. A barrier-free design opens up
entirely new possibilities, which is reﬂected in the more delicate
and more ﬂexible cooling duct routing.

N

PKD

Steel chip-evacuation element
for machining depths up to 1.5xD, Ø > 22 mm
PCD cutting edge across the centre to be used into
the solid; brazed PCD tool with screwed-on steel
chip-evacuation element.

Solid carbide chip-evacuation element
for machining depths up to 1.5xD, Ø < 22 mm
PCD cutting edge across the centre to be used into
the solid; brazed PCD tool with brazed solid carbide
chip-evacuation element.

53

DRILLING

DRILLING

2 DRILLING•

PCD drills

p. 58

•

Solid carbide drills

p. 72

55

DRILLING
DRILLING

PCD DRILLSIn high-volume series production, when very high quantities are required and the primary
focus is on costs per component and cycle time, PCD drilling tools are the ﬁrst choice in theautomotive and supplier industry. They are the ultimate benchmark with regard to the surface
quality to be manufactured and sharpness, as well as service life performance.
The group of metallic lightweight materials, especially aluminium alloys, makes particular demandsof the PCD tools here. These tools are characterised by their ability to perform burr-free machining
in aluminium alloys, prevent thermal damage to the component and take account of the demand forhigh wear resistance on the cutting edges.

SOLID CARBIDE DRILLSIn 1973, Gühring produced the ﬁrst solid carbide drills, which quickly became the standard tool for
demanding machining tasks. The tools have a high performance capability thanks to the carbide cutting
material and special tool geometry and they create bores with outstandingly accurate dimensions.
A signiﬁcant contributing factor to the success of Gühring drilling tools is the uniquely high degree of
production depth in the industry. All competencies required or tool production are bundled together under one
roof: our self-produced carbide, our in-house mechanical and plant engineering, our own coating technology
and our expertise in geometry development ensure technological leadership when it comes to rotatingmachining tools.

57
DRILLING

DRILLING

DRILLING

PCD DRILLS

59

AUTOMOTIVE / DRILLING / PCD DRILLSCYLINDER HEAD – BOLT HOLESTWIST PCD DRILLDRILLING

The bolt hole connects the cylinder head to the cylinder block. Drilling depths of 8 to 10xD and tightposition tolerances are deﬁning characteristics of the mounting hole and make reliable chip evacuation
essential. Typical problems in aluminium machining – such as the formation of build-up on the cuttingedges or welded-on layers – need to be prevented and chips need to be removed quickly.

1

Step 1:
Solid carbide pilot boring tool
(required for pre-cast bores)

2

APPLICATION EXAMPLE
Twist PCD drill
Material

AlSi7

Geometry (Ø in mm)

10.60 mmvc (m/min)

400

Feed (mm/rev)

0.58

Speed (rpm)12,000

Position accuracy (mm)< 0.3

Cylinder shape (mm)< 0.012

Step 2:
Machining into the solidwith corner-tipped PCD drill

DRILLING

Groove form optimally adapted toaluminium alloys and cutting geometry
for improved chip removal, moreconvenient chip formation and low
machining forces.
Special cooling duct routing for
maximum wall thicknesses and rigidity.

Ø from 4.0 mm can be
executedpolished chip spaces for improved
chip removal up to 10xD

REVAMPED CHIP EVACUATION
The geometry of the spiral-ﬂuted drilling tool with PCD
corner tipping is speciﬁcally adapted to the machining ofaluminium alloys. A wide open groove proﬁle and polishedchip spaces ensure reliable chip evacuation.

N

PKD

HA

2

Step 2:
Machining into the solid

61

AUTOMOTIVE / DRILLING / PCD DRILLSCYLINDER HEAD – SPARK PLUG

DUALTWIST PCD STEP DRILLDRILLING

The series production process for a spark plug bore usually uses three tools: pilot drill, step drill
and reamer. In order to reduce the cycle time, these can be combined into a single step tool.
However, with a 1-shot solution, the diameter increment on the tool causes varying cutting forces.
The chip formation also acts differently, as well as the wear. These differences need to be offset
by sophisticated tool solutions.

Machining takes place into the solid (1-shot solution).
The 1-shot variant is not possible for pre-cast bores due to the position tolerances.

APPLICATION EXAMPLE
DualTwist PCD step drill
Material

AlSi7

Geometry (Ø in mm)

11.42 / 23.00

vc (m/min)

376

Feed (mm/rev)

0.4

Speed (rpm)

5,200

DRILLING

reduction of heat input into thecomponent due to reduced
cutting forces

The continuous slope of the spirals andpolished chip spaces optimise chip
removal up to 12xD.

30 % CUTTING FORCE REDUCTION
With the DualTwist solution, we achieve soft cutting thanks to theuniform rake angle across all diameters. This results in a higher contact
ratio for the guide chamfers, therefore increased smoothness andimproved position accuracy. The cutting forces are evenly distributed
across all diameters. The DualTwist PCD step drill minimises machining
forces thanks to its special groove geometry.

N

PKD

63

AUTOMOTIVE / DRILLING / PCD DRILLSCYLINDER HEAD – INDEX BORE

PCD DRILL REAMER
DRILLING

Dowel pins, which ensure precise positioning, are used to ﬁx the position of the cylinder cap on
the cylinder head. An index bore with a drilling depth of 2xD is required on the cylinder head forthe dowel pins; this is conventionally produced using two tools.

Machining takes place into the solid.
A pilot boring tool is only required for pre-cast bores to ensure
centric positioning of the PCD drilling tool.

APPLICATION EXAMPLE
PCD drill reamer
Material

AlSi7

Geometry (Ø in mm)

8.00

vc (m/min)

200

Feed (mm/rev)

0.32

Speed (rpm)

8,000

Circularity (μm)<7Surface ﬁnish (μm)

< Rz 6.3

DRILLING

integrated pre-drilling stage for
maximum process reliability
The combination of drills and reamers in just one
tool results in a signiﬁcant cycle time reduction.
monoblock manufactured PCD drill reamer for
maximum accuracy up to IT 7 tolerance

TWO IN ONE
The PCD drill reamer from Gühring creates IT 7 bore qualities
with just one tool. The integrated pre-drilling stage reduces
the allowance for ﬁnishing, prevents the drill from running on
and guarantees reliable chip evacuation. Finishing produces ahighly precise ﬁt for the positioning of the dowel pins.

N

PKD

HSK-A

65

AUTOMOTIVE / DRILLING / PCD DRILLSWISHBONE – BALL AND SOCKET JOINT BORE

PCD CONTOUR DRILLDRILLING

Socket joint machining on the wishbone is particularly challenging due to the large radius.
Machining creates high cutting forces that can cause vibrations. Chip evacuation is also difficult due
to very long chips. Gühring tools ensure a reliable solution thanks to their special geometry.

1

Step 1:Pre-machining
PCD step drill

2

Step 2:Finishing
PCD countersink

APPLICATION EXAMPLE
STEP 1Pre-machining

STEP 2FinishingMaterial

AlSi17

AlSi17

Geometry (Ø in mm)

7.00 / 50.00

Radius 18.00

vc (m/min)

191

173

Feed (mm/rev)

0.2

0.3

Speed (rpm)

1,216

1,490

1

DRILLING

Machining into the solid means that the
PCD insertion edge wears faster comparedto the other cutting edges. Despite this,the tool works cost-effectively thanks to
exchange being possible on site.

special step geometry for machiningthat is optimised to the cutting forces
and reliable chip evacuation

SUCCESS ONE STEP AT A TIME
The radius of the ball and socket joint bore is pre-machined inindividual stages. Dividing this contour across multiple stages
results in a cutting force reduction and reliable chip evacuation.
Finishing work also does not involve cutting the entire contour
from the start and is broken down into individual stages.
This also leads to reduced cutting forces in ﬁnishing work.

N

PKD

The ﬁnished contour ofthe socket joint boreis split into two cuttingedges.

2

Step 2:Finishing

Step 1:Pre-machining

67

AUTOMOTIVE / DRILLING / PCD DRILLSWHEEL RIM – MOUNTING HOLE

DUALTWIST PCD STEP DRILLDRILLING

When it comes to rim machining, and more speciﬁcally valve bores and mounting holes, optics andprocess reliability both play a major role. In addition to the conventional challenges of machining
aluminium alloys, very tight ﬁts and a signiﬁcant safety aspect cause difficulties for manufacturers.

Mounting hole:
Highly spiral-ﬂuted PCD
step drill with DualTwist
technology

Valve bore:
Drilling into the solidwith PCD step drill

APPLICATION EXAMPLE
Mounting hole with DualTwist
PCD drill

Valve bore with PCD step drill

Material

AlSi7

AlSi7

Geometry (Ø in mm)

16.00 / 34.00

12.00 / 17.00 with radius 2.00

vc (m/min)

277

264

Feed (mm/rev)

0.4

0.3

Speed (rpm)

5,500

7,000

Surface ﬁnish (μm)

< 6.3

< 6.3

DRILLING

MACHINING ALUMINIUM
RELIABLY
DualTwist technology minimises machining forces.
The special geometry facilitates chip formation and improveschip removal. This means maximum process reliability for
mounting holes in aluminium rims.

N

PKD

optimised chip removal using acontinuous spiral slope andpolished chip spaces

reduction of heat input into thecomponent due to reduced
cutting forces

HA

Mounting hole:
Highly spiral-ﬂuted
DualTwist PCD step drill

69

AUTOMOTIVE / DRILLING / PCD DRILLSTRANSMISSION CASE – MOUNTING HOLE

PCD DRILL THREAD MILLING CUTTERDRILLING

Oil hole drilling requires a combination of two work steps: drilling into the solid, conventionallywith a solid carbide tool then with solid carbide thread milling cutters. A changeover to PCD isnecessary to reduce the number of tools, resulting in shorter main times and downtimes.

PCD drill thread milling cutterFirst the tool is drilled into the solid.
Drilling: n = 8000 rpm at 0.12 mm/rev
Then the thread is circularly milled.
Milling: n = 10000 rpm at 0.08 mm/rev

DRILLING

increased service life due to the
combination of solid carbide drillingand circular thread milling in one
PCD drill thread milling cutter

possible from M12

CLEVERLY COMBINED
The drill thread milling cutter guarantees a burr-freethreaded hole up to 1.5xD thanks to sharp PCD cuttingedges. Threads can be reliably drilled out and inserted
into aluminium alloys using just one tool.

N

PKD

71

DRILLING

DRILLING

SOLID CARBIDE DRILLS73

AUTOMOTIVE / DRILLING / SOLID CARBIDE DRILLSCYLINDER HEAD – OIL GALLERY BORE

DRILLINGSPIRAL-FLUTED SOLID CARBIDE
DEEP-HOLE DRILL RT 100 T ALU
Reliable chip evacuation is essential due to the combination of very high machining depths of
up to 30xD and the machining of aluminium with an Si content of > 3 %. Due to the silicon content,
the material tends to stick to the cutting edge, which must be prevented at all costs.
The production of the cylinder head as a whole also requires long service lives with
reduced machining times and maximum process reliability.

1
Step 1:
Pilot boring
Solid carbide drill

2

Step 2:FinishingSpiral-ﬂuted solid carbide
deep-hole drill

APPLICATION EXAMPLE
STEP 1:
Pilot boring with solid
carbide drill

STEP 2:
Solid carbide deep-hole drill

Material

AlSi7

AlSi7

Geometry (Ø in mm)

7.05

7.03

vc (m/min)

332

221

Feed (mm/rev)

0.24

1.0

Speed (rpm)15,00010,000

Step 2:Finishing,spiral-ﬂuted solid carbide deep-hole drill

DRILLING

2

ALU SPECIALISTThe cutting geometry of the spiral-ﬂuted deep-hole
drill RT 100 T ALU has been speciﬁcally optimised togenerate chips that are perfectly shaped so that they
can be removed quickly and easily from deep bores.
The design of the ﬂutes with 15° helix angle ensures aconsiderably shorter chip evacuation route.

Ncarbide specially designed for the machining ofaluminium alloys produced in-house

Very high cutting parameters; for example,
14 % feed from the diameter possible.
Nominal diameter of Ø 3.00-16.00 mm.

optimum tool stability and cooling75

AUTOMOTIVE / DRILLING / SOLID CARBIDE DRILLSCRANKSHAFT – OIL BORE

DRILLING

SOLID CARBIDE
DEEP-HOLE DRILL RT 100 T
The crankshaft converts the force transmitted from the piston to the connecting rod into a rotational
movement. The connecting rod bearing is lubricated via transverse bores within the crankshaft.
These transverse bores are manufactured during multiple machining steps using Gühring drilling
tools. The sloping entry and exit of the bore are a particular challenge here.

1

Step 1:
Pilot drill
Ø 5.008 mm

2

Step 2:
Solid carbide deep-hole drill
Ø 5.000 mm

3

Step 3:
Solid carbide countersinking toolØ 5.500 mm

APPLICATION EXAMPLE
Solid carbide pilot drill

Solid carbide deep-hole
drillCountersinking tool

Material

38MnVs6

38MnVs6

38MnVs6

Geometry (Ø in mm)

5.008

5.000

14.000vc (m/min)

70

71

60

Feed (mm/rev)

0.12

0.2

0.2

Speed (rpm)

4,450

4,500

1,350

DRILLING

SELF-PRODUCED SOLID CARBIDEFOR THE HIGHEST STANDARDSThe design of the chip ﬂutes with a high surface ﬁnish, a rake
angle of 30° and the adapted cutting geometry of the deep hole
drill concentrates fully on optimally forming the chips and removing
them quickly and easily out of deep bores. From the productionof the cutting material to the coating of the RT 100 T, everything iscompleted in-house and comes from our own production facilities.

P

2

Step 2:
Solid carbide deep-hole drill

77

MILLING•

PCD side and face milling cutters

p. 82

•

PCD slot drills

p. 104•

PCD contour milling cuttersp. 108MILLING

3 MILLINGMILLING
PF 1000 G
The PF 1000 G with its brazed cutting edges stands out due to its easy operation.
With a cutting edge length of 8 mm, it is suitable for roughing as well as ﬁnishing.
MILLING-Ø 32-125 mm as standard, available from stockmonoblock design with HSK-63 A
burr-free components after milling

PF 3000 G
The PF 3000 G is the successor of the PF 1000 G and stands out due to its additive-manufactured“Smart Cap” chip guide cover. This guarantees a deﬁned chip evacuation, an optimised coolant supply
and complete wear protection against erosion of the body.
-Ø 32-80 mm as standard, available from stock (other dimensions on request)
almost chip-free components
achievable surface ﬁnish of up to R z=5

PF 3000
μm-accurate axially adjustable cutting edges ensure maximum ﬂexibility when using the PF 3000.
Three different cutting geometries are available to choose from. The spindle load is reduced thanks to
the lightweight aluminium body.
-Ø 63-250 mm as standard, available from stockcompatible with conventional tool holders (HSK or SK)
achievable surface ﬁnishes of up to R z=2

HPC MILLING CUTTER FOR ROUGHING
This HPC milling cutter has been specially developed for roughing.
It stands out due to its large chip spaces, robust cutting inserts and chip-evacuation elements.

-

Ø 63-160 mm as standard, available from stock
up to 8 mm cutting depth possible
almost chip-free components

HPC MILLING CUTTER FOR FINISHING
This HPC milling cutter has been specially developed for ﬁnishing work. It offers an extremely highnumber of cutting edges, axially closed chip spaces and cutting edges that can be adjustedwith μm-accurate precision.
-

Ø 50-160 mm as standard, available from stock
almost chip-free components
extremely high feed rates (up to 60,000 mm/min)Diameterrange

Rz (μm)

7 mm

32-125 mm≥5Suitable for
MQL

Cutting edge
concept

See page

Yes

Brazedcutting edges

p. 84

Cutting
depth

Diameterrange

Rz (μm)

6 mm

32-80 mm≥5

Suitable for
MQL

Cutting edge
concept

See page

Yes

Brazedcutting edges

p. 88

Cutting
depth

Diameterrange

Rz (μm)

5 mm

63-250 mm≤ 3.2

Suitable for
MQL

Cutting edge
concept

See page

Only 1 duct

Adjustable
cutting edges

p. 92

Cutting
depth

Diameterrange

Rz (μm)

8 mm

63-160 mm>5Suitable for
MQL

Cutting edge
concept

See page

Yes

Adjustable
cutting edges

p. 98

Cutting
depth

Diameterrange

Rz (μm)

2 mm

50-160 mm≤ 3.2

Suitable for
MQL

Cutting edge
concept

See page

Yes

Adjustable
cutting edges

p. 98

MILLING

Cutting
depth

MILLINGMILLING

PCD SIDE AND FACE MILLING CUTTERS

83

AUTOMOTIVE / MILLING / PCD SIDE AND FACE MILLING CUTTERS
WITH BRAZED CUTTING EDGESCYLINDER BLOCK – CONTACT SURFACE MACHINING

HSC PCD FACE MILLING CUTTERPF 1000 G
MILLING

When milling contact surfaces on the cylinder block, it is essential that the machining is burr-freein order to reduce reworking costs. In line with this, PCD cutting edges are recommended for sideand face milling as the cutting edges remain sharp for a very long time despite high loads whenmachining aluminium alloys, therefore guaranteeing low-burr components.

APPLICATION EXAMPLE
Sealing surface machining
on the oil sump side
Material

AlSi9

Geometry (Ø in mm)

80.00

vc (m/min)

2,512

Feed (mm/rev)

1.1

Speed (rpm)10,0002

Step 2:
Bearing cover face milling
Cutting depth 1.0 mm

1Step 1:
Sealing surface face millingon the oil sump side
Cutting depth 0.5 mm

BURR-FREE MILLINGNMILLING

The compact design of the PF 1000 G and the high number of
cutting edges make cost-efficient HSC machining possible.
It roughs and ﬁnishes at high speeds and with large cutting depths.
Brazed cutting edges guarantee simple operation with any setup effort. Unlike conventional exchange systems, no spare partsstorage is required.

PKD

radial coolant outlets
for effective internal coolingbrazed PCD cutting edges with
8 mm cutting edge length formachining shoulders and recesses

integrated balancing screws
for high speeds

Up to 22 cutting edges
ensure maximum feed
rates with the best surface
ﬁnishes.

monoblock design with HSK 63 A
(other interfaces on request)

HSK-A

1

Step 1:
Face milling
Sealing surface on the oil sump side85

PCD face milling cutter PF 1000 G
Cutting material

4°

PF1000G

WN

TypeShank form

PKD
PF 1000 G
HSK-A

P
M
K
ä

N
S

• for fibre-reinforced plastics (FRP)• for graphite• with internal coolingH

l2

MILLING

S

d1

B

A

0,01 A-B

l1

Article no.
d1 ±0.05

S

mm
32.00
40.00
50.00
63.00
80.00
100.00125.00HSK-A 63
HSK-A 63
HSK-A 63
HSK-A 63
HSK-A 63
HSK-A 63
HSK-A 63

32
ISO

Hardness

40

l1

l2

mm

mm

100
100
100
100
100
100
100

8.0
8.0
8.0
8.0
8.0
8.0
8.0

50

fz (mm/z) / Ø
63
80

Graphite
CFK GFK
Aramid

8
10
12
14
16
18
22

125

vc
ap max = 7.00 mm

N

100

Z

ae max = 0.75 x D≥ 7% Si≥ 14% Si≤ 8 μm

1600
500
1000

0.11
0.08
0.20

0.12
0.09
0.20

0.15
0.10
0.20

0.15
0.10
0.20

0.15
0.10
0.20

0.15
0.10
0.20

0.15
0.10
0.20

−

400

0.10

0.11

0.12

0.12

0.12

0.12

0.12

86

3016
Code no.
32.00040.00050.00063.00080.000100.000
125.000

MILLING

AUTOMOTIVE / MILLING / PCD SIDE AND FACE MILLING CUTTERS
WITH ADJUSTABLE CUTTING EDGESVALVE BODY – CONTACT SURFACESPCD FACE MILLING CUTTER
SMART CAP PF 3000 GMILLING

Whether you are performing side or face milling on the cylinder head, with electric engine housingsor for machining transmission components, chip-free milling is becoming increasingly important in
the automotive industry. This technology can reduce or completely eliminate component rinsing
processes after mechanical machining, for example. Quality assurance is still at the forefront,
however. When delivering engines, the risk of impurities due to chips is minimised. The risk of thesecausing premature failure during subsequent operation decreases.

Face milling of the contact surfaces
with PF 3000 G Smart Cap(Chips must not get stuck in the cavities of the component)

APPLICATION EXAMPLE
Valve body
Material

AlSi10Mg

Geometry (Ø in mm)

50.00

vc (m/min)

2,544

Feed (mm/rev)

1,620

Speed (rpm)16,200Surface ﬁnishes (μm)

< 6.3

BARRIER-FREE DESIGNNMILLING

The additive-manufactured Smart Cap of the PF 3000 G enablesdeﬁned chip evacuation, optimised coolant supply and wear
protection for the base body. The three-dimensional chip-evacuation
elements ensure the chips are redirected away from the component.
The face milling cutter also provides easy operation: After reaching
the end of its service life, the Smart Cap can be easily replaced –process reliability is increased without any set-up effort.

PKD

Available as a standard toolØ 32 / 40 / 50 / 63 / 80 mm. Other diameters
up to 125 mm on request.
Additive-manufactured, three-dimensional coolingducts optimise the temperature control of the PCD
cutting edge.
The Smart Cap reaches up to the chip space
and therefore protects the holder against
erosions. The cap can be replaced on site by
the customer.

Brazed chip-evacuation elements incombination with internal cooling ducts are
100 % reliable in guiding chips away fromthe workpiece – even with minimum quantity
lubrication.

HSK-A

89

PCD face milling cutter PF 3000 G
Cutting material

4°PF3000
G

WN

Type

PKD
PF 3000 G

Shank form

HSK-A

Article no.

4070

P
M
K
ä

N
S

• for fibre-reinforced plastics (FRP)• for graphite• with internal coolingH
MILLING

0,01 A-B

d1

S

A

B

l2
l1

d1 ±0.05

S

mm
32.00
40.00
50.00
63.00
80.00

HSK-A 63
HSK-A 63
HSK-A 63
HSK-A 63
HSK-A 63

32
ISO

Hardness

40

l1

l2

mm

mm

100
100
100
100
100

8.0
8.0
8.0
8.0
8.0

50

fz (mm/z) / Ø
63
80

Graphite
CFK GFK
Aramid

8
9
10
14
16

125

vc
ap max = 6 mm

N

100

Z

ae max = 0.75 x D≥ 7% Si≥ 14% Si≤ 8 μm

1600
500
1000

0.11
0.08
0.20

0.12
0.09
0.20

0.15
0.10
0.20

0.15
0.10
0.20

0.15
0.10
0.20

0.15
0.10
0.20

0.15
0.10
0.20

−

400

0.10

0.11

0.12

0.12

0.12

0.12

0.12

90

Code no.
32.00040.00050.00063.00080.000Smart Cap for PCD face milling cutter PF 3000 G

WN

PF3000G

Cutting material

4°

Type

PKD
PF 3000 G

P
M
K

S
H

ä

• Smart Cap for article no. 4070
• for fibre-reinforced plastics (FRP)• for graphite• with internal cooling• incl. clamping screw
MILLINGN

Article no.
for d1
mm
32.00
40.00
50.00
63.00
80.00

4069
Code no.
32.00040.00050.00063.00080.00091

AUTOMOTIVE / MILLING / PCD SIDE AND FACE MILLING CUTTERS
WITH ADJUSTABLE CUTTING EDGESTRANSMISSION CASE – CONTACT SURFACEPCD FACE MILLING CUTTER
PF 3000
MILLING

When machining contact and sealing surfaces, it is essential to adhere to the deﬁned surface
ﬁnishes. Brazed and non-adjustable side and face milling cutters often have limited scope when it
comes to these requirements. This is why axially adjustable PCD cutting edges are used to achievedeﬁned surface ﬁnishes, such as Rz 10-15 μm. These can be perfectly adapted to the machining
task.

2

Step 2:
Sealing surface face milling
Transmission oil sump side
Cutting depth 0.5 mm

1

APPLICATION EXAMPLE
Sealing surface face milling
Transmission oil sump side
Material

AlSi9

Geometry (Ø in mm)

125.00vc (m/min)

4,710

Feed (mm/Z)

0.08

Speed (rpm)12,000Feed rate (mm/min)

17,280Surface ﬁnish (μm)

Rz = 5

Step 1:
Face milling of the contact surface
Engine side
Cutting depth 0.5 mm

FLEXIBLE AS STANDARDNMILLING

The PF 3000 offers maximum ﬂexibility due to the axiallyadjustable cutting edges and the various cutting edge
geometries that are available as standard. This means
it can perfectly adapt to the relevant machining task.
Most importantly, with diameters over 100 mm, the load on themachine spindle is reduced thanks to the lightweight design
with the aluminium body.

PKD

The cutter heads are available from Ø 63 to 250 mm and hold up to
36 PCD cutting edges depending on the diameter. The PCD cuttingedges are available with different geometries and can be reground
up to three times.

A coolant distribution plate (up to and including Ø 125 mm with a coolant
distribution screw) ensures optimum distribution of the supplied coolant
to the cutting edges.

balancing screws for
optimum smoothness

milling bodymade of lightweight,
high-strength aluminium

1

2

93
93

HSC PCD face milling heads
Cutting material-

PF3000WN

TypePF 3000

P
M
K
ä

N

• axially adjustable with μm-accurate precision• order PCD clamping holders article no. 4204 separately• defined roughness through selection of cutting edge types• order GM 300 cutter head holders article no. 4362 or 4231 separately• coolant distribution screw article no. 4203 (order separately for Ø 63-125 mm)

S
H
MILLING

d3

d1

d2

B

B-B
B
l1

Article no.
d1 ±0.05

d2

d3

l1

mm

mm

mm

mm

kg

63.00
80.00
100.00125.00160.00200.00250.00

49.00
65.00
85.00
110.00145.00185.00235.00

22.00
27.00
32.00
40.00
40.00
60.00
60.00

40.00
50.00
50.00
63.00
63.00
63.00
63.00

0.34
0.61
0.94
1.77
2.94
4.38
7.32

ISO

N
N

Hardness≤ 7% Si≤ 14% Si
Cu
CuZn / CuSn

94

vc
max
6000
2000
2000
2000

63

80

Z

fz (mm/z) / Ø
100
125
160

ap max = 5 mm
Rz 2 - 4200

Code no.

8
10
14
18
24
28
36

250

Art. 4204 30,000
Art. 4204 30,300
0.05 - 0.20
0.05 - 0.20
0.05 - 0.20
0.05 - 0.20

4201

63.00080.000100.000
125.000
160.000
200.000
250.000

63
vc

6000
2000
2000
2000

80

fz (mm/z) / Ø
100
125
160

ap max = 5 mm
Rz 10 - 25

200

250

Art. 4204 30,200
0.10 - 0.25
0.10 - 0.25
0.10 - 0.25
0.10 - 0.25

HSC PCD clamping holders
PKD

Cutting material
WN

PF3000TypePF 3000

P
M
K
N

ä

S

MILLINGH• for PF 3000
• axially adjustable cutting edges with μm-accurate precision• defined roughness through selection of cutting edge types• for finishing operations, use additionally article no. 4204 30,300• several geometries can be combined together in one holderl2
l1

Article no.
Application

l1

l2

mm

mm

kg

23
23
23

7.00
7.00
7.00

0.156
0.158
0.159

Rz 2-4Rz 10-25
Wiper

4204
Code no.
30.00030.20030.300

Spare parts
G

60o

Torx

l1

Article no.
6128
Code 5.000

Clamping screwTorx

M5 x 17

20

l1
mm
17

G
M5

A
l1

Article no.
4207
Code 30.000

Washer

d1
mm
5.10

d2
mm
8

60°

d1

d2

A

A-A

l1
mm
2
G

SW

l1

Article no.
20081
Code 4.000

Ball pressure screw

l1
mm
10.00

G

SW

M4

2.000

95

Coolant distributor
Cutting material
WN-

PF3000SurfaceTypePF 3000• for PF 3000
• coolant distribution screw (for Ø 63-125)• coolant distribution plate (for Ø 160-250)
MILLING
G

SW

l1

Article no.
l1
mm
39
47
48
58
11
11
11

96

G
M10
M12
M16
M20
-

SW
mm
8
10
14
17
-

4203
Code no.
63.00080.000100.000
125.000
160.000
200.000
250.000

Cutter head holders SK
SK

Product information

d1

d3

d2

• for holding milling cutter heads• balance quality grade: G6.3 / 15,000 rpm• SK according to DIN ISO 7388-1 shape AD/AF• dor central and decentralised internal cooling;
resulting in an improvement in process andservice life
• coolant supply, shape AD/AF• for holder Ø 40, additionally with 4 thread bores
for mounting cutter heads with tool attachment
in accordance with DIN 2079 and enlarged
installation Ø d2

• incl. milling cutter lock screw article no. 4908
and drive dogs

MILLING

Scope of delivery

l1l2

Article no.
SK
40
40
40
40
50
50
50
50

Arbor Ø d1
mm
22
27
32
40
22
27
32
40

d2
mm
48
58
78
88
48
58
78
88

l1
mm
35
40
50
50
35
40
50
50

l2
mm
19
21
24
27
19
21
24
27

4231
Code no.
22.04027.04032.04040.04022.05027.05032.05040.050GÜHROJET cutter head holders HSK-AGÜHROJET

SK

d3

d1

d2

Product information• HSK-A according to ISO 12164-1/DIN 69893-1• for holding milling cutter heads• balance quality grade: G6.3 / 15,000 rpm• according to DIN 69882-3• for central and decentralised internal cooling;
resulting in an improvement in process andservice life
• for holder Ø 40 and Ø 60, additionally with
4 thread bores for mounting cutter heads withtool attachment in accordance with DIN 2079
and enlarged installation Ø D2

Scope of delivery• incl. milling cutter lock screw article no. 4908 anddrive dogs

l1

l2

Article no.
HSK-A d3
63
63
63
63
63
80
80
80
80
80
100
100
100
100
100

Arbor Ø d1
mm
22
27
32
40
40
27
32
40
60
40
27
32
40
60
40

d2
mm
50
60
78
120
89
60
78
120
160
89
60
78
120
160
89

l1
mm
50
60
60
60
60
50
50
60
70
60
50
50
60
70
60

l2
mm
19
21
24
27
27
21
24
27
40
27
21
24
27
40
27

kg
1.1
1.3
1.5
2.7
2.7
1.8
2.1
3.3
6.3
3.3
2.9
3.3
4.2
7.2
4.2

4362
Code no.
22.06327.06332.06340.063140.063
27.08032.08040.08060.080140.080
27.10032.10040.10060.100140.100

97

AUTOMOTIVE / MILLING / PCD SIDE AND FACE MILLING CUTTERS
WITH ADJUSTABLE CUTTING EDGESCYLINDER HEAD – COMBUSTION CHAMBER SIDE

HPC MILLING CUTTER
PRE-MACHINING AND FINISHINGMILLING

Adjustable side and face milling cutters are the benchmark when it comes to very high surface
ﬁnish requirements, such as a roughness of < 5 μm, or a deﬁned roughness of 10-25 μm. This
type of machining has been revolutionised by the HPC side and face milling cutter from HollfelderGühring. Using interchangeable chip-evacuation elements made of carbide, the HPC milling cutter
guarantees maximum process reliability with deﬁned chip evacuation, less cleaning effort and low
tool costs thanks to extremely high feed rates.

Finishing on combustion chamber side
HPC milling cutter, ap = 0.5 mm

APPLICATION EXAMPLE
Finishing
Combustion chamber side
Material

AlSi9

Geometry (Ø in mm)

125.00vc (m/min)

5,890

Feed (mm/rev)

0.15

Speed (rpm)15,000Surface ﬁnish (μm)

≤ 3.2

Step 1:Pre-machining(standard range p. 100)MILLING

1

THE PINNACLE OF EFFICIENCY
Due to the large number of PCD cutting edges – e.g. 27 cuttingedges for a diameter of 125 mm – it is possible to achieve feed
rates of up to 60,000 mm/min with the Gühring HPC milling cutters.
A sophisticated, deﬁned chip evacuation process ensures almost
chip-free components. The interchangeable cutting edges
can be reground up to 10 times.
In addition to classic ﬁnishing, the roughing cutter stands out in
pre-machining with a cutting depth of up to 8 mm and 15 cuttingedges with a diameter of 125 mm.

N

PKD

adjustable cutting edges,
exchangeable and canbe reground up to
10 times

integrated coolant outlet

exchangeable chip-evacuation
elements made of carbide

2

Step 2:Finishing(standard range p. 102)99
99

HPC milling cutter for pre-machining

WN

Ø D2
ØD

MILLING

PCD cutting edge

Roughing cutter Q9934 – with HSK 63 shape A
ØD

Ø D2

mm

mm

63
80
100
125
160

66.74
83.74
103.74128.74163.74Z

L

max. rpm

Shank

Drawing no.

Article no./code no.

100
110
110
123
123

29,00023,00018,00015,00012,000

HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A

Q 9934-6300 1063 R
Q 9934-8000 1163 R
Q 9934-1000 1163 R
Q 9934-1250 1263 R
Q 9934-1600 1263 R

20005 63.000
20005 80.000
20005 100.000
20005 125.000
20005 160.000

L

max. rpm

Shank

Drawing no.

Article no./code no.

29,00023,00018,00015,00012,000

HSK100-A
HSK100-A
HSK100-A
HSK100-A
HSK100-A

Q 9934-6300 1010 R
Q 9934-8000 1110 R
Q 9934-1000 1110 R
Q 9934-1250 1210 R
Q 9934-1600 1210 R

20005 63.001
20005 80.001
20005 100.001
20005 125.001
20005 160.001

mm
6
9
12
15
18

Roughing cutter Q9934 – with HSK 100 shape A
ØD

Ø D2

mm

mm

63
80
100
125
160

66.74
83.74
103.74128.74163.74

100

Z

mm
6
9
12
15
18

100
110
110
123
123

Cutting inserts and accessories for the HPC milling cutter for pre-machining

Article no.

Cutting material

R

F

Drawing no.

PKD30
PKD30

0.8

20° / 45°20°

W9934-03300410R
W9934-08300470R

20375
Code no.
99.34099.341MILLING

PCD cutting inserts for the HPC roughing cutter

L

Chip-evacuation element (including screw),
chip-evacuation element set

Article no.

Milling cutter diameter

Drawing no.

63-160E63009934

20075

Code no.
63.000

Spare parts
Clamping screw
Article no.

Drawing no.

333053343

E333053343

Adjusting screw
Article no.

Drawing no.

333045922

E5785-1

101

HPC milling cutter for finishingL

HSK 100-A /HSK 63-AWN

ØDMILLING

Standard range Q9936 – with HSK 63 shape A for maximum feed rates
ØD

Z

mm

L

max. rpm

Shank

Drawing no.

Article no./code no.

32,00031,00028,00024,00020,00015,000

HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A

Q 9936-5000 1063 R
Q 9936-6300 1063 R
Q 9936-8000 1163 R
Q 9936-1000 1163 R
Q 9936-1250 1263 R
Q 9936-1600 1263 R

20004 50.101
20004 63.101
20004 80.101
20004 100.101
20004 125.101
20004 160.101

max. rpm

Shank

Drawing no.

Article no./code no.

32,00031,00028,00024,00020,00015,000

HSK 100-A
HSK 100-A
HSK 100-A
HSK 100-A
HSK 100-A
HSK 100-A

Q 9936-5000 1010 R
Q 9936-6300 1010 R
Q 9936-8000 1110 R
Q 9936-1000 1110 R
Q 9936-1250 1210 R
Q 9936-1600 1210 R

20004 50.103
20004 63.103
20004 80.103
20004 100.103
20004 125.103
20004 160.103

max. rpm

Shank

Drawing no.

Article no./code no.

31,00028,00024,00020,00015,000

HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A
HSK 63-A

Q 9933-6300 1063 R
Q 9933-8000 1163 R
Q 9933-1000 1163 R
Q 9933-1250 1263 R
Q 9933-1600 1263 R

20004 63.106
20004 80.106
20004 100.106
20004 125.106
20004 160.106

max. rpm

Shank

Drawing no.

Article no./code no.

31,00028,00024,00020,00015,000

HSK 100-A
HSK 100-A
HSK 100-A
HSK 100-A
HSK 100-A

Q 9933-6300 1010 R
Q 9933-8000 1110 R
Q 9933-1000 1110 R
Q 9933-1250 1210 R
Q 9933 -1600 1210 R

20004 63.108
20004 80.108
20004 100.108
20004 125.108
20004 160.108

mm

50
63
80
100
125
160

9
12
15
21
27
33

100
100
110
110
123
123

Standard range Q9936 – with HSK 100 shape A for maximum feed rates
ØD

Z

mm

L
mm

50
63
80
100
125
160

9
12
15
21
27
33

100
100
110
110
123
123

Standard range Q9936 – with HSK 63 shape A for lower spindle power
ØD

Z

mm

L
mm

63
80
100
125
160

9
12
15
18
24

100
110
110
123
123

Standard range Q9936 – with HSK 100 shape A for lower spindle power
ØD

Z

mm

L
mm

63
80
100
125
160

9
12
15
18
24

102

100
110
110
123
123

Cutting inserts and accessories for HPC milling cutters for finishing

PCD cutting inserts for HPC finishing milling cutters
Suitability

Cutting length

Cutting material

PKD10

PKD30

Article no.

20371

20374

Rz

Drawing no.

2-10
2-10
10-25

W9930-0320 0445 R
W9931-0120 0445 R
W9931-0320 0445 R

99.30099.34099.32099.30099.34099.320W9930-1000 0445 R

99.33099.330Code no.

mm
for a good surface ﬁnish
for low-burr millingfor deﬁned roughness depth
Wiper insert (in combination
with code no. 99.300 or 99.320)

5
5
5
5

Chip-evacuation element (including screw),
chip-evacuation element set

Article no.

Milling cutter diameter

Drawing no.

50-57.99
58-69.99
70-89.99
90-124.99
125-250

E5000 9936
E6300 9936
E8000 9936
E1000 9936
E1250 9936

20071

Code no.
50.10163.10180.101
100.101
125.101

Spare parts
Clamping screw
Article no.

Drawing no.

302308411

E5538

Adjusting screw
Article no.

Drawing no.

333045922

E5785-1

103

MILLING

LPCD slot drills Z=2
Cutting material

PKD

Cutting direction

R

HA

WN

Cutting data page 146

MILLING

d1

d2

d3

r

l2
l3
l1
Article no.
d1

d1

d2 h6

d3

l1

l2

l3

r

mm

mm

mm

mm

mm

mm

6.00
6.00
6.00
8.00
8.00
10.00
10.00
12.00
12.00
14.00
14.00
16.00
16.00
18.00
18.00
20.00
20.00

3.70
4.70
5.70
7.40
7.40
9.40
9.40
11.20
11.20
13.00
13.00
15.00
15.00
17.00
17.00
19.00
19.00

51
51
57
63
63
72
72
83
83
83
83
100
100
100
100
100
100

6.0
8.0
8.0
8.0
12.0
8.0
16.0
8.0
16.0
8.0
16.0
12.0
20.0
12.0
20.0
12.0
20.0

14.0
14.5
20.0
26.0
26.0
30.0
30.0
36.0
36.0
36.0
36.0
50.0
50.0
50.0
50.0
48.0
48.0

0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1

5492

Z
Availability

mm
4.000
5.000
6.000
8.000
8.001
10.00010.001
12.00012.00114.00014.001
16.00016.00118.00018.001
20.00020.001± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02

104

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2



















PCD slot drills Z=2
Cutting material

PKD

Cutting direction

R

Cyl

WN

MILLING

Cutting data page 146

d1

d2

d3

r

l2
l3
l1
Article no.
d1

d1

d2 h6

d3

l1

l2

l3

r

mm

mm

mm

mm

mm

mm

6.00
6.00
6.00
8.00
8.00
10.00
10.00
12.00
12.00
14.00
14.00
16.00
16.00
18.00
18.00
18.00
18.00
20.00
20.00

3.70
4.70
5.70
7.40
7.40
9.40
9.40
11.20
11.20
13.00
13.00
15.00
15.00
17.00
17.00
17.00
17.00
19.00
19.00

70
70
75
100
100
100
100
100
100
100
100
150
150
125
125
150
150
150
150

6.0
8.0
8.0
8.0
12.0
8.0
16.0
8.0
16.0
8.0
16.0
12.0
20.0
12.0
20.0
12.0
20.0
12.0
20.0

14.0
14.5
20.0
26.0
26.0
30.0
30.0
36.0
36.0
36.0
36.0
50.0
50.0
50.0
50.0
50.0
50.0
48.0
48.0

0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1

5493

Z
Availability

mm
4.00
5.00
6.00
8.00
8.00
10.00
10.00
12.00
12.00
14.00
14.00
16.00
16.00
18.00
18.00
18.00
18.00
20.00
20.00

± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2





















105

PCD slot drills Z=3
Cutting material

PKD

Cutting direction

R

HA

WN

Cutting data page 146

MILLING

d1

d2

d3

r

l2
l3
l1
Article no.
d1

d1

d2 h6

d3

l1

l2

l3

r

mm

mm

mm

mm

mm

mm

14.00
14.00
16.00
16.00
18.00
18.00
20.00
20.00

13.00
13.00
15.00
15.00
17.00
17.00
19.00
19.00

83
83
100
100
100
100
100
100

8.0
16.0
12.0
20.0
12.0
20.0
12.0
20.0

38.0
38.0
52.0
52.0
52.0
52.0
50.0
50.0

0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1

5495

Z
Availability

mm
14.00
14.00
16.00
16.00
18.00
18.00
20.00
20.00

± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02

106

3
3
3
3
3
3
3
3










PCD slot drills Z=3
Cutting material

PKD

Cutting direction

R

Cyl

WN

MILLING

Cutting data page 146

d1

d2

d3

r

l2
l3
l1
Article no.
d1

d1

d2 h6

d3

l1

l2

l3

r

mm

mm

mm

mm

mm

mm

14.00
14.00
16.00
16.00
18.00
18.00
20.00
20.00

13.00
13.00
15.00
15.00
17.00
17.00
19.00
19.00

100
100
150
150
150
150
150
150

8.0
16.0
12.0
20.0
12.0
20.0
12.0
20.0

38.0
38.0
52.0
52.0
52.0
52.0
50.0
50.0

0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1

5496

Z
Availability

mm
14.00
14.00
16.00
16.00
18.00
18.00
20.00
20.00

± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02± 0.02

3
3
3
3
3
3
3
3










107

MILLINGMILLING

PCD CONTOUR MILLING CUTTERS

109

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERSWISHBONE – BEARING BORE

PCD CONTOUR MILLING CUTTER
The wishbone is a part of the wheel suspension and connects the body to the wheels.
For medium-sized vehicles, the wheel suspension makes up 20 % of the vehicle's total weight.
This is why the wishbone is topologically optimised. Wishbones are quite unstable,
thin-walled and difficult to clamp, so cutting forces must be kept as low as possible.
MILLING

1

2

Step 2:
Circular milling for groove profileand bore exit face finishing

APPLICATION EXAMPLE
Bearing bore
Material

AlSi7

Geometry (Ø in mm)

75.00

vc (m/min)

1,767

Feed rate (mm/min)

3,750

Speed (rpm)7,500

Step 1:
Bore entry chamfering

2

HSK-A

deﬁned groove proﬁle

MILLING1axis angle forgentle cutting

Integrated vibration
damper compensates for
up to 70 % of vibrating.

WELL DAMPEDThe PCD complex tool combines face milling, circular contour millingfor groove proﬁles and retracting face milling of the underside. Thanks
to the combination of these three machining steps, it is not necessary
to change the tool during this already unstable clamping process.
The axis angle of the milling cutter ensures soft cutting. An integrated
vibration damper reduces the vibration by up to 70 %. The uniform
cutting maximises process reliability and therefore the service life.

N

PKD

111

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERSWHEEL CARRIER – WHEEL BEARING BORE

PCD CONTOUR MILLING CUTTER
The wheel carrier is part of the unsprung mass of the vehicle. In general, the lower the mass of
the unsprung components, the better the driving characteristics. The wheel carriers as part of thismass should be as light as possible and are therefore increasingly made using aluminium alloys
and machined using multiple spindles.
MILLING

1

Step 1:
Face milling

2

Step 2:
Circular roughing

3

Step 3:Finishing

APPLICATION EXAMPLE
Pre-machining and ﬁnishing of the main bore
Material

AlSi7

Geometry (Ø in mm)

60.00

Feed rate (mm/min)

2,500

Speed (rpm)10,000MILLING

1 - 3

3. Finishing

2. Circular roughing

1. Face milling

OBSTRUCTION IMPOSSIBLE
Circular milling can offset the allowance, preventing the toolfrom swinging up. The combination of different machining
tasks reduces the cycle time.

N

PKD

113

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERS

MASTER BRAKE CYLINDER – SEALING RING GROOVESPCD SLOT CUTTER
The master brake cylinder converts the pressure exerted on the brake pedal into hydraulic braking
power. For this purpose, sealing rings are placed in sealing ring grooves, which are responsible forthe pressure build-up. The precise positioning of the groove is essential for tightness. Due to thedelicate component geometry, it is necessary to keep the cutting forces as low as possible.
MILLING

Circular millingof oil sealing ring grooves
PCD slot cutter

APPLICATION EXAMPLE
Sealing ring groove surface
machining
Material

AlSi7

Geometry (Ø in mm)

24.70

Feed rate (mm/min)

1,500

Speed (rpm)5,500

CROSS-CUTCONTROLS VIBRATIONThe PCD slot cutter is equipped with cross-cut toothing toalmost equalise the cutting forces. The spacing between
the cutting edge positions means that they engage at
different times. As a result, the tool does not vibrate and thesealing ring groove can be produced to a high quality.

PKD
MILLINGN

A special cutting edge geometry
with cross-cut toothing
signiﬁcantly reduces the cutting
forces.

Separated cutting edges ensure
soft cutting and prevent the toolfrom swinging up.

radius at the diameter for
maximum rigidity

HA

115

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERS

EXHAUST TURBOCHARGER – COMPRESSOR HOUSINGPCD CONTOUR MILLING CUTTER
The compressor side of the turbocharger sucks in combustion air and supplies it to the engine
in compressed form. The many simultaneous interventions in the aluminium alloy result in hightorques, which in turn leads to an extremely high spindle load. Particular attention needs
to be paid to reduced cutting forces and high process reliability.
MILLING

1

2

Step 1:Pre-machining
the diameter and contact faces,ﬁnishing the chamfer
Step 2:Finishing
the diameter and contact faces,ﬁnishing the groove2

Step 2:Finishingdiameter ﬁnishing with Z=2

contact surface ﬁnishing with Z=2

MILLING

cutting edge distribution for reduced
cutting forces

ﬁnishing
Radius with Z=2

circular milling
Groove with Z=5

EFFECTIVELY COMBINED
The division of the processing tasks into pre-machining
and ﬁnishing guarantees maximum process reliability.
In addition, the cutting forces are minimised by the
distribution of the cutting edges.

N

PKD

special cutting edge
geometry to reduce thecutting force

1

HSK-A

Step 1:Pre-machining

1
117

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERSSCROLL COMPRESSOR – MACHINING FIXED SPIRALSPCD CONTOUR MILLING CUTTER
The scroll compressor consists of two spirals that move in opposite directions to compress gases.
One scroll is stationary; the other moves eccentrically. Since the ﬁxed scroll has to be perfectly
coordinated to the moving scroll, these components are subject to very tight shape and position
tolerances.
MILLING

1

Step 1:Pre-machining the scroll compressor
Solid carbide milling tool
into the solid with ap = 6 mm2

Step 2:Finishing the scroll compressor
with the PCD milling tool

APPLICATION EXAMPLE
Pre-machining

FinishingMaterial

AlSi12

AlSi12

Geometry (Ø in mm)

10.00

8.00

vc (m/min)

942

704

Feed (mm/min)

6,000

2,700

Speed (rpm)30,00028,000Surface ﬁnish (μm)-

Rz ≤ 3.2

Line shape (μm)

-

≤ 10

Perpendicularity (μm)

-

≤ 25

2

Step 2:Finishing

MILLING

HSK-E

The combination of the monoblock tooland the appropriate shrink ﬁt chuck
ensures maximum rigidity.

soft cutting thanks to 12° axis angle
very long, continuous
cutting edge for optimum
surface ﬁnishes

RELIABLE COMPRESSING
Extremely soft cutting is achieved with a 12° axis angle and acontinuous, very long cutting edge. The monoblock design of thecontour milling cutter in combination with the appropriate Gühring
shrink ﬁt chuck ensures maximum rigidity.

N

PKD

119

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERS

STRUCTURAL COMPONENTS – SHOCK ABSORBER MOUNTINGPCD CONTOUR MILLING CUTTER“Lightweight construction” has been a trend in the automotive industry for many years. Body parts
are increasingly being manufactured with aluminium alloys. The shock absorber mounting as oneof these lightweight components combines minimal weight with maximum rigidity. The structuralcomponent is thin-walled and correspondingly difficult to clamp and machine.
MILLING

1

1

Step 1:
Mounting hole2

Step 2:
Circular milling
Shock absorber mounting hole3

Step 3:
Drilling and face countersinking
Shock absorber mounting hole4

Step 4:
Drilling and reaming
Fitting hole

The PCD contour milling cutter combines several machining
steps – drilling, milling, reaming, face countersinking – in one tool.
In addition to reducing tool change times and saving space instorerooms, the main time is also signiﬁcantly shortened.
With the cutting edges running across the centre,
milling into the solid is no problem.

N

PKD

HA

1 - 4
121

MILLING

GOING FLAT OUT

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERS

BUMPER – MOUNTING HOLE

PCD CONTOUR MILLING CUTTER
Bumpers are made from aluminium to absorb the impact energy. Aluminium proﬁles have very thinwalls and tend to have a high burr formation during drilling operations. The aluminium proﬁles also
push off very quickly due to their thin walls and length.

MILLING

Aluminium profile drilling
PCD helix milling cutter
Up to 3.00 mm plunging depth per revolution

WITHOUT PRESSURENMILLING

Instead of plunging with a drill on the face side as usual, thebumper mounting hole is created using a helix milling cutter,
which plunges into the bore in a circular motion. This therefore
avoids the unidirectional machining pressure on the face sidewhich arises during conventional drilling. The load on the
proﬁle to be machined is much lower. This machining strategy
guarantees a burr-free result, especially in proﬁle machining.

PKD

The load on the component
is reduced during helicalmilling compared to drilling.
This means that evendelicate proﬁles can bemachined reliably.

up to 3.0 mm plunging depth
per revolution

123

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERSSUSPENSION STRUT SHAFT – BEARING BORE

PCD CONTOUR MILLING CUTTER
The suspension strut shaft is part of the wheel suspension and is included in the chassis. It
transfers the load from the spring damper system to the spring link. Machining aluminium alloys
involves milling into solid material. The thinness of the component and the depth of the bearing borepose particular challenges.
MILLING

Bearing bore
Machining into the solidwith a circular milling strategy,plunging depth is 2.5 mm/rev

APPLICATION EXAMPLE
Finishing the bearing bore
Material

AlSi7

Geometry (Ø in mm)

30.00

vc (m/min)

1,696

Feed rate (mm/min)

2,800

Speed (rpm)18,000MILLING

HSK-Asmooth transitions in the chip spacefor optimum chip removal

cooling directed towards the rear at the
cutting edges and in the chip space forreliable machining

10° axle angle ensures
soft cutting
helical path per revolution
ap = 2.5 mm

A SOLID GRASPThe helix of the contour milling cutter and the spacing of
the cutting edges ensure a soft cut to reliably cope withhelical milling into the solid. Smooth transitions in the chip
space prevent chip blockages. Optimised cooling directed
towards the rear reliably removes the chips from the deep
blind hole and prevents tool damage.

N

PKD

125

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERS

EXHAUST GAS TURBOCHARGER –HOSE CONNECTION FOR COMPRESSOR HOUSING

PCD BELL TOOLMILLING

The compressor in the turbocharger sucks in combustion air and supplies it to the engine in theform of compressed air. When machining the hose connection for air output, a special groove
proﬁle must be created to increase the adhesion of the hose to the compressor housing.
The tool must be prevented from pushing off at all costs during machining in order toprecisely reproduce the contour.

APPLICATION EXAMPLE
Finishing the hose connection
Material

AlSi7

Geometry (Ø in mm)

53.00

vc (m/min)

1,664

Feed (mm/min)

1,500

Speed (rpm)10,000HSK-AThe component isprevented from pushing
off thanks to distributed
cutting.

ESTABLISHING A
SECURE CONNECTION
Maximum rigidity is ensured thanks to the reinforced basebody of the bell tool. The cutting edges are divided into threeparts to reduce the enormous cutting pressure during radiusmachining. This generates a soft cut to produce the perfectgroove proﬁle for a maximum coefficient of friction between thehose and the connection.

N

PKD

127

MILLING1

reinforced base bodyfor precise machining

AUTOMOTIVE / MILLING / PCD CONTOUR MILLING CUTTERSCYLINDER BLOCK – CRANKSHAFT BEARING BORE FOR OIL GROOVEPCD SLOT CUTTER
The crankshaft converts the energy generated during the combustion of the fuel-air mixture into
a rotational movement. Oil grooves reduce friction and therefore reduce the load between the
crankshaft and bearing. Due to an unfavourable diameter to length ratio, the machining tends
to cause push off.
MILLING

128

The contour milling cutter has a solid carbide shank,
which prevents its tendency to vibrate. The radial
cutting forces are also almost completely eliminatedby the cutting index and opposing teeth. This ensuresmaximum process reliability.

N

PKD

1

Separated cutting edges
and a special cutting edge
geometry with opposing teeth
ensure soft cutting and preventthe tool from pushing off.

solid carbide shankfor maximum rigidity

HSK-A

129

MILLINGIMMOVABLE GROOVESMILLINGMILLING

BALL TRACK MILLING CUTTERS
FROM GÜHRING
the high-performance solution for the machiningof homokinetic joints

131

The Gühring Tool dispensing systems optimise tool
storage and management. Gain more safety foryour tool storage with the TM systems 326, 426
and 526 and optimise processes in manufacturing
regarding tool consumption and cost transparency.

Gühring Tool Management Software

TECHNICAL SECTION135

TECHNICALSECTION

4

Technical section

PCD and PCBN as cutting materials
affect how the tools are used. Apart from the hardness, themain difference lies in the carbon‘s affinity for iron. For thisreason, PCD is well suited to non-ferrous metals, whereas
PCBN is better suited to ferrous metals and is tougher, butalso less hard.

Schematic structure of PCD
Filler: Fills the spaces between the interlinked individual diamond
crystals

Schematic structure of PCBNTECHNICALSECTION

In contrast to natural monocrystalline diamond, polycrystalline
diamond (PCD) is the result of a synthesis process developedin the 1950s. Both PCD and polycrystalline cubic boron nitride(PCBN) are composite materials with differing amounts ofhard material and are used for cutting metals. There are key
differences in the structure of these cutting materials which= Hard material

136= Filler for PCD / binder for PCBN

Binder: Can influence the toughness and wear resistanceTechnical section

There are essentially three types of PCD, which are used foran outstanding surface finish. Medium grain can be useddifferent applications. The types are differentiated by their

universally for milling, reaming and drilling. Mixed grain isgrain size. Fine grain is used for reaming as it produces

mainly used for milling and offers good wear resistance.

Fine grain < 4 μm

Medium grain 5-10 μm

Mixed grain 2-20 μm and 10-35 μm

Diamond content: 90 %Diamond content: 92 %Diamond content: 95 %Used for: Reaming

Used for: Universally

Used for: Milling

Very sharp cutting edges foroutstanding surface finishes.

Outstanding abrasion resistance andgood surface finishes.

Good results with very abrasive materials.

Very high wear resistance.

PCBN types
Three different types are mainly used to produce PCBN tools.

slightly, moderately and severely interrupted cutting. CBN 30

The hardness, toughness and thermal conductivity grow as

is a solid PCBN cutting material which is used as a cutting

the CBN content increases. CBN 10 is one of the lower grades

insert without a carbide substrate when turning and milling.

of PCBN. CBN 20 is one of the higher grades of PCBN which

CBN 30 is also suitable for roughing, for large cutting depths

are substantially harder and tougher. Both types are suitableand for very abrasive materials during severely interrupted

for turning, milling and reaming in specific applications.

cutting.

A distinction is made here between continuous cutting and

CBN 10 (lower-grade PCBN)CBN 20 (higher-grade PCBN)CBN 30 (solid PCBN)ä

CBN content: 50-75 %ä

CBN content: 80-95 %ä

CBN content: 80-95 %ä

WITH carbide substrate

ä

WITH carbide substrateä

WITHOUT carbide substrateä

Used for: Turning, milling, reaming
for continuous cutting and slightlyinterrupted cuttingä

Used for: Turning, milling, reaming
for severely interrupted cuttingä

Used for: Turning, millingfor severely interrupted cuttingä

Finishing and roughing workääFinishing work

Roughing work and machining very
abrasive materials, for large cutting
depths137

TECHNICALSECTION

PCD types

Technical section

Manufacturing PCD and PCBN tools
Manufacturing PCD tools

Individual diamond crystals

Two-layered round blank

Segments = cutting edges

Tool carrier

TECHNICALSECTION

PCD tools are manufactured from synthetic individual

twolayered round blank, which is cut into small segments using

diamond crystals, which are sintered onto a carbide substratewire eroding or laser cutting and brazed onto a tool carrier.

under pressure and at a high temperature. This produces a

Manufacturing PCBN tools

Boron nitride powder

Two-layered round blank

Segments = cutting edges

Tool carrier

PCBN is manufactured in a chemical process under highhard material, before the cutting material is sintered onto thepressure and at temperatures in excess of 1500 °C. In contrast

metal carrier.

to PCD, with PCBN a metallic or ceramic binder is used for the138Technical section

Features of PCD and PCBN for use in cutting tools

PCD

PCBN

the ideal cutting material for non-ferrous metals

the ideal cutting material for iron-based alloys•

Use of grain sizes between < 1 μm-40 μm•

Fine, medium, coarse or mixed grain•

The higher the diamond content and the coarser
the grain, the higher the wear resistance of the
PCD.

•

Less hard than diamond (2,600-4,500 HV)•

Chemically resistant to ferrous materials•

High level of temperature and wear resistancefor iron-based alloys

Fine grain provides very sharp cutting edges andresults in very good surface finishes on thecomponent.

•

Binding systems:
Ceramic: heat-stable
Metallic: tough•High level of hardness (8,000 HV)••Resistant to wear when machining non-ferrous
metals, fibre-reinforced plastic or ceramic

CBN content:
Lower-grade CBN 50-75 %:Hard machining, continuous to interrupted cutting
Higher-grade CBN > 80 %: Cast iron machining•

Due to the carbon‘s high affinity for iron,ferrous materials cannot be machined despite
the high level of hardness. As a result of chemical
diffusion wear and the formation of iron carbide,
machining materials under the influence ofpressure and temperature would cause the PCD
cutting edge to wear out prematurely.
This issue can be solved by using PCBN.

TECHNICALSECTION•

139

Technical section

Features of PCD and PCBN for use in cutting tools
When machining material, the cutting materials are generally

for as long as possible. PCD and PCBN are ultra-hard cutting

subject to extreme loads such as heat, impacts, or abrasive

materials offering high performance on account of theirand chemical influences, in particular on the cutting edges.

impressive properties with respect to hardness, toughness,

Therefore, the cutter must be able to withstand these influences

resistance to thermal shock, and chemical resistance.

Benefits for the user
TECHNICALSECTION•

greater productivity, due to a longer service life and higher cutting speeds, for example•

lower costs per workpiece•

the most appropriate cutting material is selected for customer-specific tools,
in order to meet special requirements and maximise added value•

very good surface finish•

very high level of accuracy•

high profitability as it can be re-tipped multiple times

140

Technical section

Comparison of PCD properties

8000 HV

500
m/min
and more

PCD

TECHNICALSECTION300
m/min1600 HV
PCD

850 HV
50 m/min

VHM

VHM

HSS
HSS

Hardness

Cutting speed

18.84
sec.

5000 mExample for AlSi7:
Ø 20 mm
f=0.4 mm/rev
100 mm drilling depth

PCD

HSS

1000 m
3.14
sec.

1.88
sec.

200 m

VHM

VHM
PCD

Machining time

HSS

Tool life141

Technical section

Balancing – the Gühring standard
PCD/PCBN tools used for machining usually work at a highthis can cause premature wear, inaccuracies in the machining,rotational speed. If the mass is unequally distributed in its

and damage to the machine.

rotational symmetry on rotating bodies, rotors or tool systems,

TECHNICALSECTION

Static imbalance

Dynamic imbalance

Static imbalance is caused by asymmetry in the toolsystem, as a result of which the centre of gravity axis
does not run through, but rather parallel to the rotary
axis of the rotating body. During the rotation,
this produces circular mechanical oscillations which
run at right angles to the rotary axis.

Dynamic imbalance manifests itself as an imbalance
moment on the rotary axis. At its ends, it causes
circular oscillations which are offset by 180°.
The centre of gravity of the rotating body remains
in the rest position, whilst the axis sways due to the
opposing circular movement.

Centre of gravity axis

Centre of gravity axis

Rotary axis

Rotary axis

Calculating the imbalanceThe

imbalanceisameasureindicating

how

much

Imbalance is measured on a balancing machine. In order to do

asymmetrically distributed mass is located from the rotaryso, the balancing specifications of the tool to be measured needaxis in the radial direction. The imbalance is specified in gmm.

to be entered. The calculated imbalance can be compensated

The distance dimension e indicates how far a part‘s centre ofusing various methods.

gravity is from the rotary axis.

Centre of gravity distancee to rotary axis

U = m∙e
U = Imbalance in gmm
m = Mass in kg
e = Centre of gravity distance in μm

142

Compensation hole
Rotary axis

Technical section

Balancing
In order to prevent the tool running irregularly and to

Static imbalance is already checked in the design engineering

compensate for an asymmetric distribution of mass, all PCD/

stage using a virtual environment, and is compensated by

PCBN special tools are checked for imbalance before they arebalancing surfaces and bores.

used.

Tools with a protruding length of up to 160 mm
are balanced statically on one plane.

1st balancing plane

Dynamic balancing

Tools with a protruding length of over 160 mm arebalanced dynamically on two planes, provided that the
distance between the two balancing planes is at least
100 mm and the geometry permits this.

1st balancing plane

2nd balancing plane

Balancing methods
Imbalance can be compensated using the following methods.
•

Balancing by attaching balancing screws with threadlocker•

Balancing by milling compensating surfaces in the form of balancing pockets and balancing surfaces•

Balancing by drilling balancing bores

Balancing screws withthreadlocker

Balancing surfaces

Balancing bores

Balancing pockets

143

TECHNICALSECTION

Static balancing

At Gühring, the balancing specifications are always noted on production
drawings and customer drawings. If the user does not state any
specifications themselves, the Gühring standard (G 6.3; n=10,000 rpm) willbe specified. At the customer‘s request, tools can also be fine-balanced
provided that the geometry permits this.

i

Further information about balancing requirements for rotating tool systems
can be found in DIN 69888.

TECHNICALSECTION

PERMISSIBLE RESIDUAL IMBALANCE / BALANCING BODY MASSIN GMM / KG OR E IN ΜM

1000

G

G

100

6.3

2.5

G

1

10

STANDARD BALANCING QUALITY

1

0.1
100

1000

10000

MAX. OPERATING SPEED IN RPM

144

10000014145
45
TECHNICALSECTION

Technical section

Cutting data
Below you will find the cutting values for rotary machining.

•

Component drawing (tolerances, allowance, tool length,
etc.)

•

Machine data (spindle power, clamping details,
HSK/SK/BT interface, etc.)•

Wet or MQL machining (1 or 2-channel and the relevant
manufacturer)•

Material designation

These values are intended as a guide. Following an initialinspection of the machining, the values can be adjusted further
in order to ensure the best possible quality and cycle times. If
exact information is provided with respect to the application
details below, tailored cutting data can be determined for thetool:

Reaming < IT 8
Material

Cutting speedvc (m/min)

Recommended
allowance (Ø mm)

TECHNICALSECTION

Tool diameterFeedfz (mm/tooth)<Ø5< Ø 10< Ø 16< Ø 24<Ø5

Wrought aluminium alloys

0,5-1

> 200

200-400

200-400

200-500

0,04-0,12 0,08-0,15 0,1-0,2< Ø 10< Ø 16< Ø 240,1-0,25

Cast alum. alloy < 9 % Si

0,5-1

> 250

250-500

250-700

250-800

0,04-0,12 0,08-0,15 0,1-0,20,1-0,25

Cast alum. alloy > 12 % Si

0,5-1

> 250

250-500

250-800

250-800

0,04-0,12 0,08-0,15 0,1-0,20,1-0,2

Cast alum. alloy up to 17 % Si 0,3-0,5> 200

250-400

250-550250-550

0,04-0,12 0,08-0,15 0,1-0,20,1-0,2Magnesium alloys> 250

250-600

300-800

300-1000 0,04-0,10 0,08-0,15 0,1-0,20,1-0,2

0,3,-0,5

Drilling / boring
MaterialFeedfz (mm/tooth)Cutting speedvc (m/min)

Tool diameter<Ø5< Ø 10< Ø 16< Ø 24<Ø5< Ø 10< Ø 16< Ø 24

Wrought aluminium alloys< 200

150-400

150-450

150-500

0,04-0,10

0,08-0,15

0,1-0,20,1-0,25

Cast alum. alloy < 9 % Si

< 250

250-500

250-700

250-1000

0,04-0,12

0,08-0,15

0,1-0,20,1-0,25

Cast alum. alloy > 12 % Si

< 250

250-500

250-800

250-1000

0,04-0,12

0,08-0,15

0,1-0,20,1-0,2

Cast alum. alloy up to 17 % Si < 200

250-400

250-550250-550

0,04-0,12

0,08-0,15

0,1-0,20,1-0,2Magnesium alloys

250-600

300-800

300-1000

0,04-0,10

0,08-0,15

0,1-0,20,1-0,2< 250

Milling (end milling cutter, contour milling cutter, article no. 5492 / 5493 / 5495 / 5496)
Material

Cutting speedvc (m/min)

Tool diameter<Ø5< Ø 10< Ø 16Feedfz (mm/tooth)< Ø 24<Ø5< Ø 10< Ø 16< Ø 24

Wrought aluminium alloys> 200

200-400

200-400

200-500

0,04-0,12

0,08-0,15

0,1-0,20,1-0,25

Cast alum. alloy < 9 % Si

> 250

250-500

250-700

250-1200

0,04-0,12

0,08-0,15

0,1-0,20,1-0,25

Cast alum. alloy > 12 % Si

> 250

250-500

250-800

250-1200

0,04-0,12

0,08-0,15

0,1-0,20,1-0,2

Cast alum. alloy up to 17 % Si > 200

250-400

250-550

250-800

0,04-0,12

0,08-0,15

0,1-0,20,1-0,2Magnesium alloys

250-600

300-800

300-1000

0,04-0,10

0,08-0,15

0,1-0,20,1-0,2> 250

Face milling (face milling cutter, article no. 3016 / 4201 / 4070)
Material

Cutting speedvc (m/min)
Roughing

FinishingFeedfz (mm/tooth)
Roughing

Finishing

Al-Knetlegierungen600-2500

600-2200

0,08-0,25

0,05-0,15

Cast alum. alloy < 9 % Si

800-3000

800-3000

0,08-0,25

0,08-0,15

Cast alum. alloy > 12 % Si

800-2800

800-2800

0,08-0,25

0,08-0,15

Cast alum. alloy up to 17 % Si 600-2000

600-2000

0,05-0,2

0,05-0,15

Magnesium alloys

800-2800

0,04-0,10

0,08-0,15146

800-2800

Technical section

Gühringdesignation

Classification

Area of application,
properties

averagegrain size

Diamondcontent

PCD 10..

Ultra-fine grain

Aluminium and low-alloyed AlSi compounds, magnesium alloys, copper, titanium,
ceramics and composite materials, optimal breakage protection and cutting edge quality,
outstanding abrasion and impact resistance, highest-quality surface finishes

1 μm> 90 %PCD

PCD 20..

Fine grain

Aluminium and AlSi alloys < 10 % Si, magnesium alloys, brass, copper, bronze,wood composite materials, outstanding cutting edge quality, high abrasion resistance,
outstanding surface finishes

2-4 μmca. 90 %PCD

PCD 30..

Medium grain

Gühring standard type
AlSi alloys < 14 % Si, copper alloys, graphite and graphite composite materials,
wood composite materials, non-sintered ceramic and carbides (< 15 % binder content),
outstanding abrasion resistance, good surface finishes

5-10 μm

ca. 92 %PCD

Coarse grain

Roughing applications
AlSi alloys > 14 % Si and other abrasive machining applications, MMCs,
sintered ceramic and carbides (< 15 % binder content), extremely abrasion-resistant,high impact resistance, long tool life with acceptable to good surfaces

25 μm

ca. 94 %PCD

PCD 50..

Mixed grain

the most abrasive machining applications (e.g. > 14 % AlSi alloys, MMC,
composite materials), highest wear resistance, outstanding impact resistance,
extremely abrasionresistant with good edge quality,
long tool life with very good surface finishes

2-4 μm+25 μm

ca. 95 %PCDPCBN 10..

Lower
CBN gradewith carbide
substrate

for finishing work on e.g. hardened case hardened steels, heat-treatable steels, tool steels;
suitable for applications (in particular hard turning) involving continuous andinterrupted cutting with chip removal of < 0.5 mm, high pressure resistance,
low thermal conductivity, excellent abrasion resistance, chemical stability,
good impact strength for high removal rates, excellent surface finish and a long tool life

2 μm

50-75 %
CBN

PCBN 20..

Higher
CBN gradewithcarbidesubstrate

for machining e.g. pearlitic grey cast iron (> 45 HRC), hardened steel, tool steels andmould-making steels, powder metallurgy Fe sintered materials, alloys with a Ni/Cr base(nickel-base alloys – „superalloys“), thermal sprayed alloys & hard coatings with a Co, Ni andFe base, suitable for applications involving continuous and interrupted cutting with moderate
chip removal (typically 0.5-1.5 mm), high thermal conductivity, high fracture toughness,high-quality surface finishes

2 μm

80-95 %
CBN

PCBN 30..

Higher
CBN grade
without
carbidesubstrate

Solid PCBN cutting material without a carbide substrate for roughing workon pearlitic grey cast iron, chilled cast iron (> 45 HRC), hardened steels with high fracture
toughness, excellent wear resistance, very good chemical stability,
high specific removal rates
For use in clamping devices, drilling and boring tools, recessing tools, as well as millingheads with jaw clamps and negative rake angle geometry

15 μm

80-95 %CBN

PCD 40..

147

TECHNICALSECTION

Overview of PCD / PCBN types

Technical section

Instructions for use / troubleshooting for drilling
When performing drilling / boring work, it is essential to observe the following:•

Condition of the surface (cast edge, cast bead, unevenness)•

Depth of the bore being created•Material (abrasive, long-chipping and zirconium content)•

Overall tool length

TECHNICALSECTION

Surface has
chattermarks
or is torn up

Bore istoo large

Remedy• Check the concentricity• Reduce the speed• Select the correct drill bit• Check the condition of the tool(structure, breakage, sharpness)• Check the clamping

Borefractures

ProblemRemedy• Check the cooling: cooling ductconnected, pressure present,internal cooling blocked• Check the concentricity• Check the structure of the guidechamfers

Bore istoo smallRemedy• Increase the speed• Increase the feed rate
• Check the allowance forpre-cast bores• Check for wear on the tool

Tool notrunning true
Remedy• Check the first cut• Check for interrupted cuts
• Check the concentricity/
check for angle errors

148

Remedy• Reduce the speed• Reduce the feed rate
• Check the concentricity• Select the correct drill bit(first cut)
• Build-up on cutting edges

Technical section

Instructions for use / troubleshooting for reaming
When performing reaming work, it is essential to observe the following:
Correct number of cutting edges•

Check for interrupted cuts•

Check of the allowance and condition of the pre-machining tool•

Bore is centrically pre-machined or cast•

Check of the cutting edges in the case of pronounced misalignment

TECHNICALSECTION•

Surface has
chattermarks
or is torn up

Bore istoo large

Remedy• Check the concentricity• Reduce the speed• Check the corner radius/
corner chamfer

Conicalbore

Remedy• Reduce the speed• Reduce the feed rate
• Check the concentricity• Check for wear on the tool
• Reduce the coolant pressure

ProblemRemedy• Check the quality: position of the
pre-machining/casting quality• Reduce the pressure and heat(reduce the speed)

Bore istoo smallRemedy• Increase the speed• Increase the feed rate
• Check for wear on the tool

Tool notrunning true
Remedy• Check the first cut• Check for interrupted cuts
• Check the concentricity/checkfor angle errors• Check the pre-machining

149

Technical section

Instructions for use / troubleshooting for milling
When performing milling work, it is essential to observe the following:•

Angle of engagement max. 85 %•Condition of the surface to be milled (cast skin)•For end milling cutters: Do not exceed a plunging depth (ap) > 2xD•

Ensure a segment thickness of at least 2 mm if possible•

In the case of unstable tools, the check for interfering edges should be performed precisely using a jig and component(max. neck diameter, as large as possible, length as short as possible).

TECHNICALSECTION

Material build-up
with face milling
cutter, dull surface

Milling cutter
vibrates
Remedy• Reduce the speed• Increase the feed rate
• Check the angle of engagement• Check the clamping

150

ProblemRemedy• Shorten the face cut• Check the angle at the frontof the cutting edge
• Reduce the feed rate
• Check for wear on the
milling cutter

Technical section

Instructions for use / handling tools
Installation and adjustment instructions for our PCD/PCBN tools can be found in
the download area at www.guehring.de or can be obtained directly using the
QR code.

In order to ensure reliable process results, please proceed as follows before using the tool:
1. Check the tool
2. Check the tool adjustment devices and measuring devices
3. Check the machine spindle

TECHNICALSECTION

4. Check the cooling lubricant

Checking the tools
1. Visually inspect the cutting edge for damage
2. Check the concentricity
3. Check the flow through the cooling ducts
4. Visually inspect the interface for the following•

Cleanliness (HSK cleaned using cleaning cap, article no. 4947)•

Pressure marks on the taper or end face•

The presence of the coolant tube

5. Check the clamping devices for the following•

Cleanliness•

Damage•

The clamping force using the Senso 3000 clamping force measuring instrument, article no. 4038
(e.g. hydro expansion chuck)•

Overheating during the shrinking process (shrink chuck/annealing colours)

Checking the tool adjustment devices and measuring devices
1. Check the cleanliness of the interface (cleaned using cleaning mandrel, article no. 4914)
2. Check the concentricity using taper proofing bars, article no. 4970, 4791
3. Check the draw-in force using the HSK clamping force measuring instrument, article no. 4974, SK/BT article no. 4973

151

Technical section

Checking the machine spindle
1. Check the cleanliness (machine spindle cleaned using cleaning mandrel, article no. 4914)
2. Check for deposits, i.e. damage, on the interface (end face as well as taper area)
3. Check the spindle concentricity using taper proofing bars
4. Check the clamping force using the HSK clamping force measuring instrument, article no. 4974, SK/BT article no. 4973

Interface

Minimum draw-in force (kN)Interface

Minimum draw-in force (kN)

HSK 25

2.8

HSK 8028

HSK 32

5

HSK 10045

HSK 40

6.8

SK/BT/CAT30

6

HSK 5011

SK/BT/CAT40

12

HSK 63

18

SK/BT/CAT50

25

TECHNICALSECTION

Checking the cooling lubricant
1. Oil content•

normal: 6-8 %•Tools with guide pads: mind. 8 %2. Mix thoroughly to ensure correct lubrication (no beads of fat!)
3. Filter fineness of at least 50 μm; if necessary check the filter quality of the cooling lubricant using
the CC 3000 coolant supply measuring instrument, article no. 4076

152

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Winning project of theeLearning Award 2018:GÜHRING ACADEMY"The fundamentals of machining
in a practical, interactive e-Learning
format."GM 300
Tool holders and clamping systems
for every application

Our comprehensive standard range of tool holders andclamping systems can be found in the GM 300 catalogue.

iGÜHRING KG l Telephone: +49 74 31 17-0 l Fax: +49 74 31 17-21 279
l

l

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l

Herderstrasse 50 - 54 72458 Albstadt Germany info@guehring.de www.guehring.de

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| Printed in Germany | 2018

PCD - PCBN