Objective

Based on an analysis of the most frequent challenges encountered when machining stainless steels, Schumacher's R&D Team has developed the requirements for a completely new geometry. Drawing upon the expertise of a technical university in Germany, and Schumacher‘s modules ToolDesign and ToolSimulation, the following characteristics were defined:

  • Process stability throughout the intended tool lifespan.
  • Improved wear resistance of the tool
  • Increase of tool life in work piece materials from ISO groups M 1 and M 2
  • Increase of cutting speed
  • Reduction of chip problems and avoidance of disproportionate increase of torsional moment

During the 18-month development of project POLAR, the existing geometry for stainless steels was completely redesigned and fine-tuned to meet the new target criteria in all tool properties.

The previous geometry for stainless steel will keep its place in Schumacher's product range - the new development is especially designed for serial production using challenging materials.

The project

  1. The first project phase was implemented at Schumacher‘s - entirely on a digital basis. Engineers came up with new geometry designs based on the requirement profile and our first-hand experience with the target work piece materials. Using Schumacher’s ToolSimulation utility, each of these new designs could be tested using the digital work piece (materials from Group M 1 and M 2) first.
  2. Upon analysing the results and identifying the most successful new geometry designs, we started the physical sample production. Long-term testing allowed our engineers to evaluate the actual performance of the new geometry designs based on their meeting the project objectives.
  3. After completing the test series and finally selecting the new tap's geometry, end customers were selected to test out the POLAR geometry in a realistic production environment.
  4. Market introduction

POLAR's Properties

The POLAR geometry is applied on a PM-Substrate. It features a new combination of cutting angle and relief, a particular conicity (taper) of the cutting part, and a modified flute design to improve chip control. The standard version is equipped with very hard PVD-Coating (TiCN-Variant). The blind hole version has a 45° spiral flute and an extended flute length.

M2: Martensitic - Ferritic.
M1: Austenitic.
P1: Ferritic - Martensitic.

 



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