4. GE 100 with Support - A Real Winner

Workpiece: Cold formed bolts in extrusion steel (Cq45) of 630 N/mm2. Basic dimensions: Ø 5.2-0.02 x 170 mm.

Task: Turning of a bolt to Ø 3.5 +-0.1 x 3.5 mm, chamfer 0.5 x 45º.

Problem: Combining the operations "turning" and "chamfering," retaining the alignment accuracy of 1/100 mm from Ø 5.2 mm to Ø 3.5 mm. Support is a genuine problem considering the unclamped distance of 30 mm.

Solution: End operation system GE 100 with support. The support contains a sealed ball bearing with a guide bush, guaranteeing absolute concentricity. The radially adjustable clamping holder allows the exact setting of Ø 3.5 mm and chamfer 0.5 x 45º.

By choosing this tooling solution, our expert not only reduced the task to one operation but also achieved extreme alignment accuract of 0.04 mm on average, better than required. The 2 indexable inserts generally achieve 8000 parts, whereby the deviation from the nominal diameter never exceeded 0.02 mm. Inaccuracies of the rotary machine spindle did not influence the result.

A further advantage which must be mentioned is the simple, flexible adjustment for other components. It is sufficient to change clamping holder and guide bush.

Cutting rates: v_c = 100 m/min, f = 0.12 mm/rev..

Dry machining.