magazine industry asia 3

04 EEC One new version

18 Directed High-Pressure Coolant Tooling

15 Shaft coupling with integrated torque

measurement10 Kennametal South Africa

Relocation

13 Steute RF RC 10

06 Clean In Place Systems for Pharmaceutical and

Chemical companies.

16 Spray water and dust protection in over 300

versions

Industry ASIAMagazine

The industry magazine for ASIAJULY 2013 - Issue 02

table ofC O N T E N T S

BALLUFF First magnetostrictive position measuring systems with IO-Link

De Dietrich Offers cutting-edge CIP (Clean In Place) Systems for Pharmaceutical and Chemical companies.

KENNAMETAL Kennametal South Africa Relocation

NORD Russia’s industry needs efficient drive solutions...

STEUTE sWave® wireless standard allows for modern and flexible production concepts

SECO TOOLS Seco advances holemaking in composites with new PCD-tipped drills

EPLAN Eplan EEC One

MAYR Shaft coupling with integrated torque measurement

080405061011131415

17

12

16

18PROSOFT ProSoft Technology® releases the 802.11n Industrial Wireless Access Point/Bridge/Repeater with Fast Roam Technology

KENNAMETAL Beyond EADE™

NORD SK 180E

TSUBAKi KABELSChLEPP Spray water and dust protection in over 300 versions

SECO TOOLSReducing Directed High-Pressure Coolant Tooling

magazine-industry-asia.com 7-20134

Eplan EEC One: New version, new languages

The key elements of this new development are even deeper integration into the Eplan Platform and increased international orientation with four additional software languages. The existing integration with support for value sets, variants and script technology has also been extended. In future, users will be able to access the parts database in the Eplan Platform directly from EEC One. Selected parts and their properties are adopted directly in EEC One and can be used for further automation purposes. The benefits are clear: Increased levels of automation for schematic production, reduced manual input and lower error levels, plus optimised, user-friendly operation. Of course, the new version supports the current Eplan Platform 2.2.

Automation with compliant representationCompanies active in the US American market need to con-figure their systems and plants not only in compliance with IEC standards, they also need effective mastery of ladder technology. The new version of the EEC One generates schematics to this typically American standard. Simple switching between IEC and

ladder views is also a bonus. Depending on the setting in EEC one, plans are generated automatically either to the IEC standard or based on ladder technology. The real practical benefit: different target mar-kets can be served from a single data source.

Multi-talented - now in 6 languagesWith four new languages (French, Spanish, Russian and Chinese), the EEC One is now all set for the global market.In conjunction with the Eplan Platform, configuration engi-neers can now generate projects automatically in their own language. The advantage: Language barriers are removed and the degree of efficiency of software use increases. Inter-national companies with cross-border locations will appreci-ate the new move - the Eplan Engineering Center One (EEC One) has already established itself in Germany and English-speaking countries within the space of a year.

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magazine-industry-asia.com 7-2013 5

Position measuring systems from Balluff stand for the precise detection of measurement paths in large parts of the manufacturing and assembly industry. With the Micropulse BTL6 Profile PF IO-Link model, Balluff is the first company worldwide to equip magnetostrictive position measuring systems with IO-Link.

All measured values and status data are sent digitally and via a simple, three-wire cable via IO-Link master to the control level. The contact-free transducers with intelligent communication interface are used preferably where comprehensive IO-Link designs are to simplify the configuration, accelerate the installation and reduce costs during wiring. Thanks to IO-Link, the end results are streamlined and productive manufacturing solutions that permit automatic configuration during running operation and transparent diagnostics down to the process level.

PF magnetostrictive position measuring systems from Balluff are characterized by their flat construction and a robust, shock-, vibration- and soiling-insensitive design in enclosure rating IP 67.

Thanks to multi-magnet technology, the contact-free transducers reliably detect the measurement position and ensure absolute and precise results. Measurement lengths from 50 to 4,570 mm can be realized; the position measuring systems tolerate a vertical and horizontal offset of the position encoder to the sensor profile of up to 15 mm.

With its point-to-point connection under networks of any type, IO-Link establishes a high-performance communication channel in both directions. Against the background of increasing demand for IO-Link designs, Balluff has, with the Micropulse PF IO-Link, equipped another device from its product line with the intelligent interface. The contact-free position measurement technology communicates with a speed of 230kB, achieves a process data cycle of 1 ms and offers a resolution of 1µm. As a result, even fast movements can be reliably detected. Via M12 connectors with a standard sensor cable, the transducers are connected quickly and easily to the IO-Link master and integrated in the controller.

First magnetostrictive position measuring systems with IO-Link

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De Dietrich offers cutting-edge CIP (Clean In Place) Systems for Pharmaceutical and Chemical companies.

De Dietrich´s state-of-the-art CIP systems improve cleaning quality, reduce operating time in order to optimize reactor operations, and significantly lower solvent consumption. In addition, the repetitive cleaning cycle provides constant efficiency. CIP systems are also less labor intensive and reduce the risk of dangerous chemical exposure to workers. To meet traceability and GMP standards, pharmaceutical and chemical companies are turning to CIP systems to meet cleaning requirements.

Analytical approachThe success of CIP technology is based on the coverage of the solvent and the internal equipment parts. The main difficulty for project managers or engineers is to ensure that the CIP system will have full coverage. De Dietrich has developed a specific approach and a high- quality process that solves the full coverage problem. With this new method, CIP component selection and optimizing is very easy. A specific numeric


simulation is performed on the equipment to obtain the requested coverage, and the report is precise on type, number and localization of each spray-ball. This high-value simulation can be done for existing equipment or for equipment in the process of being manufactured. On-Site TestingTo validate equipment performances, Riboflavine or Conductivity tests can be done on existing equipment in our facilities or on customer site. With this additional step, De Dietrich experts demonstrate that requested coverage is met.

The expansion of the De Dietrich process provides a guarantee for pharmaceutical and chemical companies that the cleanability of equipment will be optimized and conform to their needs. Furthermore, all requested information (flow rate, pressure) is known in the early stages of the project.

De Dietrich offers numerous advantages for clients, from cleanability studies and tests to optimization of tank and unit designs. The company offers an extensive range of high-efficiency CIP equipment, and provides complete engineering solutions for fixed and movable CIP skids and units. GMP regulations (part 133,4) and similar (part 211.67) starts by: Equipment....shall be maintained in a clean and orderly manner.... The main concerns of the FDA concerning cleanability are:

Avoiding contamination of productAvoiding cross contamination (by improper cleaning, bad maintenance)“Call back” action of product.

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New Beyond EADE™ Solid Ceramic Endmills from Kennametal Set New Speed and Tool Life Benchmarks Machining Nickel-Based High-Temperature AlloysNew 6-flute Beyond KYS40 solid ceramic end mill from Kennametal. Perhaps the most basic assumption in machining is that cutting high-strength materials takes higher-strength tools. Proprietary nickel-based alloys used in gas and steam turbines, for example, are among the world’s strongest materials, continually being developed to allow power plants to run at much higher temperatures. This not only provides more power to those that need it, it increases plant efficiency and reduces or eliminates harmful emissions. Superalloys such as Inconel®, Waspaloy®, Rene®, and others come into play in turbine blades and other parts that require high strength, excellent high temperature creep resistance, phase stability, and resistance to oxidation and corrosion.

But machining such materials can be a slow, laborious, and cost-intensive experience. In general, solid carbide tooling commonly runs at speeds between 65 and 200 SFM (20 to 60 m/min) in such materials with limited tool life. New Beyond KYS40™-grade solid ceramic endmills from Kennametal, however, are presenting orders-of-magnitude improvements in machining high-strength nickel-based alloys, roughing at cutting speeds up to 3,300 SFM (1000 m/min) with tool life two to three times longer than comparable solid-carbide tools.

Industry FirstCutting tools made of ceramics, mainly aluminum oxide (Al2 O3) have existed since the early 20th Century. Patents on ceramic cutting tools were issued in Germany in 1913 and were commercially available in the US in the 1950s. Ceramic indexable inserts have their place today because they can operate at


higher speeds in selected applications, but solid ceramic end mills were rarely seen because such tools were more brittle than carbide and did not perform well. In fact, many turbine manufacturers have taken to producing their own solid carbide end mills in house due to the high consumption of these tools.

Kennametal’s new SiAlON KYS40 ceramic grade and the overall design of the solid ceramic endmill now offers the most effective way to rough nickel-based high-temperature alloys. “Cutting speeds on nickel-based superalloys can be up to 20 times higher compared to solid carbide end mills, and due to ceramic’s outstanding heat resistance and stronger cutting edges (negative rake), tool life can last five times longer or more,” says Thilo Mueller, global product manager at Kennametal.

The wear mechanisms and wear indication on the solid ceramic end mills is completely different from carbide, allowing running ceramic end mills far beyond the point where carbide tooling would need to be replaced. That’s also the reason that this new KYS40 grade end mill is a throw-away type of tooling to allow usage beyond regular type of wear.

Turbine Blade MachiningWhether powered by fossil fuels, hydro, or nuclear power, almost all electrical power on earth is generated by a turbine of some type. Producing, managing, and maintaining these critical components are vital to keeping the power flowing.

This puts a lot of pressure on manufacturers to continually update their machining strategies. Many factors affect this: are large numbers of similar blades required or small volumes of different blade designs? Are multiple setups and machining centers involved or single multi-axis multitasking machines? What is the CAD/CAM system being used and what is the expertise of the operators?

And, of course, what are the best tooling choices for the machining operations? Recent test results involving the new KYS40 solid ceramic end mill are insightful. First of all, the KYS40 Beyond grade ceramic

in both the four-flute and six-flute versions features an enlarged core design that improves tool rigidity and reduces deflection at high cutting speeds. Optimized end geometry and a 40-degree helix angle increase shearing action and chip evacuation.

In roughing the profile of a small turbine blade made of Inconel 718, machined dry, the EADE four-flute end mill was run at 645 m/min (2116 SFM), fed at 0.03 mm/z (0.0012 IPT). Depth of cut (ap) was 0.5 mm (0.0197 inches) and width of cut (ae) was 11.4 mm (0.866 inches). Compared to a conventional solution, the EADE four-flute mill lasted three times longer doing the roughing in less time. This application resulted in three times more parts being produced per mill.

The six-flute EADE solid ceramic end mill was tested profiling a blisk (blade integrated disk) made of Inconel 718 and run with compressed air for chip evacuation. Unlike conventional carbide tooling, roughing to near net shape creates chips closer to dust than traditional curled chips, requiring only compressed air to blow them out of the cut. Test conditions were cutting speed of 679 m/min (2228 SFM), feed of 0.03 mm/z (0.0012 IPT), and the depth of cut varied up to 0.5 mm (0.0197 inches).

The results were two blisk segments machined with one tool at a 12-minute machining time per segment, which test personnel deemed “unprecedented.”

Kennametal is offering the new KYS40 ceramic end mills in the range of 3/16 – ½ inch (4 – 12 mm). Running the tool does not require use of special clamping, the use of common high performance collet, power, or hydraulic chucks is fully sufficient, although the chuck must be able to run at the high speeds necessary for superalloy machining. To ensure highest tool life, final balancing is recommended. More information is available at www.kennametal.com.

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Kennametal South Africa - Relocation

This relocation is in alignment with Kennametal’s strategies to grow in emerging markets and expands Kennametal’s footprint in Sub Saharan Africa.

“The new facility combines numerous functions including state-of-the-art conical and surface mining manufacturing, sales, finance and administration under one roof in one location,” said Kennametal South Africa’s Managing Director Mike Hankin, a company that is a subsidiary of NYSE listed Kennametal Inc., based in Latrobe, Pennsylvania in the United States. “This new facility increases our local presence, enabling us to better serve our customers in the region with Kennametal Tricon products and services.”

The new plant enables improved, continuous and integrated material flow within the production processes; faster lead times for the supply of product to Kennametal’s customers and an enhanced competitive edge within the industry.

Kennametal has invested in state-of-the-art machinery, building and infrastructure, including Tricon equipment. With this new facility Kennametal will be able to better serve customers mainly in the Earthworks business by offering Kennametal’s complete product portfolio and custom solutions for the oil & gas industry, surface and underground mining, construction and Tricon products and technology.

The grand opening of the new facility took place with a four-day open house including a Family Day on Saturday, and a Customer and Press Day on Tuesday 7th May, 2013.

“We are excited about the new facility and look forward to the improved efficiencies it will provide to customers as well as future growth opportunities in the region,” affirmed Brian Maglosky, vice president manufacturing Integrated Supply Chain and Logistics EMEA.

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Russia’s industry needs efficient drive solutions

Bargteheide – Looking to learn about energy-efficient drive technology, Russian President Vladimir Putin and German Chancellor Angela Merkel stopped by the booth of German drive manufacturer NORD DRIVESYSTEMS on their tour of select exhibitors after jointly opening the 2013 Hannover Messe. Since the country’s last turn as high-profile partner of the world’s leading industrial fair in 2005, Russia has witnessed a surge in awareness for sustainable business practices, environmentally sound technology, and green growth strategies. Given this trend, the leaders of the two nations made NORD, a renowned provider of high-efficiency drive solutions, a port of call on their brief round of visits to major German brands and industrial innovators. Electric drives play a crucial role throughout all industrial sectors, since they constitute core components of machines and plants and have a major bearing on these systems’ total energy requirements. At this year’s booth in Hanover, NORD is showcasing a drive solution for conveyors based on integrated drive units that boast particularly low consumption. Each of these full-fledged units combines a geared motor complying with the strictest

current energy efficiency classification, IE4 (Super Premium Efficiency), with a motor-mounted frequency inverter that delivers versatile drive control. These drives were at the center of the exchange between Merkel, Putin, and NORD’s top management team. Optimizing conveying technology is a particularly effective step in the implementation of new, economically viable and ecologically progressive solutions. NORD also supplies a wide range of efficient geared motors for various other applications as well as a comprehensive portfolio of suitable power electronics. As demand for such technology is on the rise in Russia, NORD’s local activities and investments have recently been significantly expanded: an all-new manufacturing site in Saint Petersburg was inaugurated only months ago in order to further enhance NORD’s service and delivery performance for Russian customers. In addition to this plant, NORD maintains a nationwide presence throughout the country with bases in another seven Russian cities.

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SK 180E: New distributed frequency inverters from NORD DRIVESYSTEMS

Complementing the SK 200E line of frequency inverters, NORD DRIVESYSTEMS introduces the SK 180E which is mounted on asynchronous motors, just like its larger counterparts. Featuring proven ISD vector control, the SK 180E is even more cost-effective than the currently available range of decentralized units. The new inverter focuses on the core requirements of speed control and efficiency. Featuring two analog inputs and integrated process and PI controller functions, it can autonomously manage simple drive applications. It is suitable both for stand-alone variable frequency drives and for synchronized operation with several units. A typical example of the latter: distributed horizontal conveying applications requiring no positioning or encoder feedback, no special safety functions or braking resistors, and with motor power outputs from 0.25 to 2.2 kW. The SK 180E also contains all necessary functions for many fan and pump applications. Here, it can save up to 30 % energy by automatic magnetization adjustment under

partial load. Providing class C1 radio interference suppression and a discharge current below 16 mA, the SK 180E can even be operated in residential and business buildings in nearly every country in the world. For use in mobile pumps, shredders, or mixers, variable frequency drives are available complete with a conventional mains plug. The drives have typical overload reserves of 150 % for 60 seconds and briefly even up to 200 %. All distributed drive electronics from NORD follow the same simple and versatile operation concept: they can be programmed directly, by means of parameter boxes, or via computer using the free-of-charge NORD CON software. Parameters can be quickly exported to other devices using the internal system bus or Ethernet interfaces.In addition to the SK 180E and the SK 200E, which can also control diagonal and vertical conveying tasks with safety requirements up to SIL3, NORD’s decentralized solutions also include the very economic new SK 135E soft and reverse starter which can carry out simple switching tasks in logistics and conveying.

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sWave® wireless standard allows for modern and flexible production concepts : wireless sensors for industrial Automation

At the Hanover Fair, in addition to electromechanical wireless switchgear working according to the »energy harvesting« principle, the steute business field »Wireless« has introduced a new generation of wireless sensors using the sWave® wireless protocol, developed by steute and running on the 868 / 915 MHz frequency band. The RF RC 10, housed in a compact, square, thermoplastic enclosure, can be flexibly integrated in machine construction. It is equipped with reed contacts, while the cylindrical wireless sensors RF GS M25 and RF GS M30 detect the target by the GMR effect. This offers the advantage for users that the sensor can also be mounted on vibrating machines and plants because vibrations cannot

influence the GMR effect. Thus the application field for magnetic sensors has been extended.

The multi-network capability of the sWave® wireless technology permits use of several sensors within one transmission area. Bi-directional signal transmission is one of the specialities of the wireless protocol: with an in-built time delay, acknowledgement is sent of each transmission confirmation.

The sensors have a calculated life of more than one million operations and a switching frequency of max. 12,000 telegrams (incl. repetitions) per hour. They are available for transmission ranges 868 MHz (Europe & Asia) and 915 MHz (America) and can thus be applied worldwide.

For all three sensors, power is supplied by a long-life lithium battery that lasts for several years thanks to the extremely low energy consumption of the sWave® wireless protocol.

The wireless sensors have been designed for reliable position detection without wiring or pipe laying and for application in an industrial environment. Because no wires are required, steute offers electrical engineers the chance to apply non-contact sensors more flexibly than before. Thus the sensors are optimally suited to integration in plants designed on the basis of »Industry 4.0« and »Smart Factory« and are characterised by decentralised intelligence and increased flexibility.

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Seco advances holemaking in composites with new PCD-tipped drills

Seco’s new CX1 and CX2 solid polycrystalline diamond-tipped drills bring increased tool life, productivity and quality to manufacturers machining holes in composite materials. Unlike traditional PCD, vein or dual brazed tip designs, the CX1 and CX2 further prevent delamination and uncut fibres by featuring a solid PCD dome and solid PCD cap, respectively, on a solid carbide drill body. This new PCD technology has also enabled Seco to develop the industry’s first PCD three-flute geometry (CX1) for composite drilling. The CX1 and CX2 drills offer what the company deems the sharpest and strongest cutting edges currently available. This performance is possible because the new drills use solid PCD tips that can be much sharper than diamond coated drills where the coatings wrap around a drill’s cutting edges and actually create a dulling effect. Other benefits of the new solid PCD tipped drills include high cutting speeds, low friction, good heat transfer, multiple re-sharpening and high process reliability.

For effective drilling through “plain” composite materials, the third flute on the CX1 provides high levels of stability in the hole as well as decreased vibrations and improved roundness. Furthermore, the dome-shaped tip of the CX1 offers a double-angle geometry. This geometry greatly reduces uncut fibres and delamination

in composite-only applications. Grinding these highly complex types of geometries was previously impossible using conventional brazed or similar such PCD techniques. Plus, the dome cap makes it possible for the drill point to be reconditioned and resharpened up to three times.

The CX2 is a flat geometry drill point for machining stacked composite materials with layers of aluminium or titanium. With this geometry, a PCD cap is used because the drill point is a 180-degree point angle that provides efficient chip breaking and evacuation qualities. This reduces the risk of metal chips damaging the hole when transitioning between layers of metal and composites. As a result, the CX2 keeps the surface finish of the composite intact.

Both the CX1 and CX2 series include a mix of dimensions for holes that range in size from 3.26 to 9.53 (0.125” to 0.375”). Chamfers can also be incorporated into the drill designs to further increase application flexibility.For more information on the CX1 and CX2, please visit www.secotools.com/en/Global/Products/Holemaking/Drilling/PCD-Drills/

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Shaft coupling with integrated torque measurement

The torque-measuring shaft coupling ROBA®-DSM is based on the tried-and-tested backlash-free shaft coupling ROBA®-DS. This torque measurement coupling can be used in many different applications, from test stand construction to serial machines, right up to condition monitoring. The system allows easy condition monitoring of machines and systems. Using the data collected by the coupling, machines can be optimally used to capacity. The measurement of rotating parts requires the transmission of energy onto the rotating part and the transmission of data from the rotating part. Many different systems are available for this purpose. In the past, energy and data were mainly transmitted inductively. However, this principle has several disadvantages in comparison to the data transmission of the new ROBA®-DSM.

A big disadvantage of the inductive systems is that data can only be transmitted over short distances. Therefore, they work mainly using “enclosing” stators, which are also partly bearing-supported. The enclosure makes both installation and replacement far more complex. Furthermore, the installation must be carried out very precisely, as the distances are very short. Another disadvantage is the low tolerances in case of vibrations and shaft run-out. Bearing-supported systems also make a torque support mandatory. Here, it is also important to observe the installation position, so that the bearing friction torques are not included in the measurements.

Systems, which are not bearing-supported, require an installation aid in order to centre the rotor and the stator. The ROBA®-DSM does not require an enclosure and therefore only needs a small installation space. The stator can easily be mounted in any position on the circumference. When adjusting the stator, large tolerances are permitted in all directions. Potential distances of up to 5 mm are substantially larger than on enclosing systems. Another major disadvantage of the inductive systems is the usually low transmission bandwidth on analogue versions or the low data rate on digital variants. In most cases, such systems are specified up to 1 kHz. Due to the transmission of energy and measurement data via a carrier, these systems require a complex separation of signals.

The new torque-measuring ROBA®-DSM makes use of two completely separate paths for the transmission of energy to the rotor and the transmission of data to the recipient. Due to the high bandwidth of up to 3.5kHz, it can even record fast, dynamic processes reliably. The preparation of the data on the rotor permits optimum amplification and offset compensation. On the rotor there is a programmable amplifier, which is programmed via the radio interface. In this way, the customer can undertake offset compensation on the rotor even after installation. In addition, the user can adjust the address encoding and radio channel with the aid of software. Another advantage is the use of an encoded radio system in the 2.4GHz ISM band.

Therefore the operator can quickly obtain an overview over the current performance data. In addition, records can easily be made, even over extended periods of time. The evaluation of the data can then take place offline using appropriate programs such as DIADEM or also EXCEL, and other tabular calculation programs. In addition, online evaluation is possible, whereby the data are read in directly, for example using LABVIEW, and processed in real time.

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The three new type series TKA30, TKA38, TKA45 and the TKA55 complete theportfolio of closed cable carriers by TSUBAKI KABELSCHLEPP

The three new type series TKA30, TKA38, TKA45 and the TKA55 complete the portfolio of closed cable carriers by TSUBAKI KABELSCHLEPP. The TKA product family therefore comprises over 300 versions. The cable carriers with an especially tight design reliably protect cables against dirt, chips and spray water.

The design of the TKA cable carriers effectively prevents the intrusion of foreign bodies into the cable space and ensures reliable protection of the cables right up to the connection area. The TKA55 was tested according to IP54 and confirmed by TÜV NORD. The design of the side bands and the cover system protects cables against spray water from any angle and against the intrusion of dust. All TKA type series are optionally available as extremely heat-

resistant models: A special material securely protects cables against negative effects, for example from chips with a temperature of up to 850 °C.

The three new type series were developed on the basis of TKA55. Essential product features are the optimized geometry of the chain links and a triple encapsulated stroke system which allows large self-supporting lengths while being highly torsion-resistant. The integrated gliding surfaces make the cable carrier ideally suited for long travel lengths. The covers can alternatively be opened inside or outside and provide secure hold even with heavy mechanical loads, e.g. when using hydraulic cables. An internal damper system ensures noise and vibration damping.

More information on the internet at www.kabelschlepp.de/solutions2013.

TSUBAKI KABELSCHLEPP present three new type series of the TKA cable carrier

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ProSoft Technology® releases the 802.11n Industrial Wireless Access Point/Bridge/Repeater with Fast Roam Technology

The 802.11abgn Fast Industrial Hotspot is an advanced, high-speed wireless Ethernet solution designed for plant-floor automation, SCADA systems, mobile worker Wi-Fi infrastructure and process control systems. This Hotspot offers a broad range of industrial wireless capabilities including unique features such as Fast Roaming and has excellent packet-per-second performance and robust communications in demanding industrial environments.

June 2013 ProSoft Technology® is pleased to announce the release of the 802.11 abgn Fast Industrial Hotspot. The new 802.11abgn Fast Industrial Hotspot (RLX2) features breakthrough advancements in client/bridge fast roaming between access points, Ethernet packet optimization, and enhanced diagnostics.

These new capabilities provide seamless high-speed Ethernet connections for moving machines and vehicles traveling long distances in assembly plants, crane systems and mining. The secure, high speed wireless network reduces project costs, while improving productivity by eliminating mechanical festooning, rails and slip rings for economical and reliable mobile applications.

The radio’s Fast Roaming technology uses less than 50msec time between access points and provides full device bridging. The module provides secure 802.11i and 128-bit AES Encryption and operates securely in the 2.4 GHz or 5 GHz bands. It also has advanced management tools. These tools include IH Browser Utility, web server and OPC server. The microSD card will automatically store/load configurations, reducing down time. The Hotspot is designed for extreme environments and hazardous locations, including oil and gas systems. It is an ideal wireless solution for Producer/Consumer PLC/PAC networking, remote I/O, safety I/O, plant backhaul networking, remote video and mobile worker connectivity. The Hotspot utilizes extended operating temperatures of -40 to +75°C (-40°F to +167°F) and has agency approvals and certifications with Class1, Division 2 and ATEX Zone 2. The module is high shock/vibration tested. The Shock IEC is 60068 2-6 (20g, 3-Axis) and Vibration IEC is 60068 2-27 (5g, 10-150 Hz).

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There are high expectations for today’s coolant delivery tooling systems* to do more than just cool metal cutting processes. When you choose or are even forced to use coolant, functional efficiency should be at as high a level as possible and be able to present significant opportunities to release hidden productivity. Equally importantly, especially in turning operations, the modern coolant fluid delivery tooling systems must provide effective chip control.

The benefits of using coolant to remove heat and lubricate (reduce friction) are well known; with coolant usually being applied by simply flooding the machining area. Although, for coolant to be really effective, it needs to remove heat quickly from the cutting zone, and a directed high-pressure coolant flow that puts coolant precisely where it is required is much more efficient.

Challenges in cooling the metal cutting processThere are several examples of challenges found at the cross-roads of coolant application and productivity demands in machining, but one of the more striking can be taken from the aerospace materials e.g. titanium alloy Ti6Al-4V. Ti6Al-4V alloy has low thermal conductivity and low modulus of elasticity, making it a suitable material for the high-strength, heat-resistant and lightweight parts in jet engines. However, it is notoriously costly to machine because required cut¬ting speeds are typically quite low, chips are impossible to control and cutting tool life relatively short. Unbroken, long chips can result in chip jamming, subsequent tool failure and, in the worst case, damage costly parts. They can also scratch surface finishes and cause a valuable component to be scrapped.

Bird-nest-like tangles of chips generated by the metal cutting process cause significant

Directed High-Pressure Coolant Tooling


productivity losses in attended production, making it almost impossible for machines to run unattended in lights-out operations. This particularly holds true when machining with toolholders or toolblocks with conventional coolant nozzles that are not located close to the cutting edge.

While significant advancements have been made in high-pressure systems, most manufacturers still rely on flood-type coolant systems that drench coolant over a cutting tool and the component being machined to reduce heat. In addition, more flexible coolant nozzles often move, making them inaccurate when it comes to directing coolant to the cutting zone. Such systems also lack adequate control for sufficient pressure.

As flood coolant just washes over the cutting zone, it can also heat up locally to a point where a steam vapour barrier forms. This vapour then actually insulates the cutting zone and keeps heat from dissipating. To combat this situation, high-pressure cooling systems can remove heat fast enough and with enough pressure to prevent such vapour barriers from developing.

Manufacturers must also keep in mind that there are differences between high-pressure coolant delivery tooling systems. The most common of those differences involve distance from the cutting zone, or how far away a system’s coolant outlet is from the workpiece/cutting tool interface. Some system outlets may not be close enough to effectively and accurately reach the optimum point within the cutting zone for the most benefit. Systems that incorporate coolant outlets situated further away from the cutting zone must use higher pressures to compensate for the increased distance.

If a system’s coolant outlets are too far from the cutting zone, additional pumps may be needed. Comparatively, this results in higher costs to achieve the same level of results provided by a system that has outlets closer to the cutting zone. When coolant is channeled through holders then through inducers, as with Seco Tools’ Jetstream Tooling® system, coolant outlets can be arranged in very close proximity to the cutting zone, achieving better results with pressure generated from a machine’s standard

coolant pump. The need for a second high-pressure pump is thus eliminated. Benefits of directed high-pressure coolantIt is to overcome the drawbacks of existing coolant delivery systems that developers of coolant delivery tooling systems, such as Seco, have worked to optimise system performance by boosting the pressure and precision with which coolant streams are directed into cutting zones.

Systems such as Seco’s Jetstream Tooling® incorporate strategically placed coolant exit holes machined into swiveling top clamps (inducers) on insert holders. Coolant pressure, flow and the small diameter holes are what enable the acute, high-velocity stream of coolant to easily penetrate and lubricate the primary heat zone just behind the cutting edge.

Seco has discovered that providing a coolant “wedge”, very close to the cutting edge, proves most effective. This means that the system’s exit outlet positions the jetstream of coolant between the insert rake cutting zone and chip, contributing to the lifting and breaking off of the chip.

The latest generation of Jetstream Tooling® for turning, grooving and parting-off provides holders with coolant outlets directed towards rake faces, but also towards insert clearances ¬– the secondary heat zone. The coolant jet underneath provides optimal cooling just below the cutting edge. This extra coolant jet directed towards insert clearance increase tool life by another 10 percent and improves surface finish.

When coolant delivery tooling systems provide both cooling and optimised chip control, manufacturers also eliminate downtime and gain problem-free, lights-out machining capability. But just as beneficial, they are able to increase turning speeds and feeds, extend cutting tool life and improve the surface finish of the component – all because of advanced chip control. In some cases, speeds and feeds can be doubled or even tripled, and tool life can also often be doubled. This increases productivity and profitability by machining more parts faster.

Laboratory tests done at Seco with a titanium workpiece at a cutting speed of 40 m/min (130


ft/min), feed rate of 0.25 mm/rev (0.01 ipr) and 2 mm (0.08 in) depth of cut with flood coolant gave a five-minute cycle time. Researchers then applied a high-pressure coolant delivery tooling system to the operation and were able to increase the cutting speed to 80 m/min (260 ft/min) and reduce cycle time by half, as well as increase tool life by 100%.

Today’s machine tool coolant pumps generally provide between 20 bar (290 psi) and 70 bar pressure (1000 psi), which is a range more than adequate for high-pressure coolant delivery tooling systems such as Seco´s Jetstream Tooling®. Seco’s system for instance, offers the versatility to operate from low pressures with some productivity impact at as low as 5 bar (70 psi) to high pressures at 70 bar (1000 psi), and to ultra-high pressures 350 bar (5 000 psi) with the same system.

At between 20 (290 psi) and 40 bar (580 psi), significant productivity boosts with Seco Jetstream Tooling® can be seen as well as improved chip control in most applications and different workpiece materials. The performance increases with the amount of pressure and flow (l/min). And, 70 bar (1 000 psi) is quite adequate to break the most demanding chips formed from sticky, long chipping commercial materials. Applications and industriesTurning, parting off and grooving operations benefit the most from high-pressure coolant. In these operations, the contact time between the cutting edge and the part is often a few seconds or longer and defined as “continuous cuts.” The continuous cuts generate high temperature in the cutting zone, and therefore, the cutting parameters need to be adapted to prevent rapid flank wear and plastic deformation. The combination of a continuous cut and a gummy, ductile material can produce a very long, uncontrollable chip that is highly undesirable.

Most industries can benefit from high-pressure coolant, but traditionally power generation, aerospace and medical areas have adapted to this trend the most with their many exotic materials where intense chip formation management is required.

For example, titanium, often used in aerospace

and medical applications, is a poor conductor of heat, which causes high temperatures to remain in the cutting zone. This can lead to welding, galling and smearing, all of which can quickly destroy a tool’s cutting edges. To make matters worse, machining titanium produces thin, high velocity chips that are difficult to break into manageable lengths. These chips will also carry critical coolant away from the cutting zone, causing thermal damage to component surfaces. Conventional tools with high positive rakes and sharp edges can minimise the detrimental effects caused by machining titanium, but high-pressure coolant delivery tooling is needed to control chips and optimise overall machining operations. University experiments and studies con¬firm that a rapid temperature reduction in a chip as it passes over the cutting edge invokes a hardening effect, much the same way as quenching a hot piece of metal very quickly. The hardness of the titanium chip is increased. The combination of the direction of flow, the wedge effect and pressure of the coolant against the chip with its increased hardness force the chip to break into small, easily managed pieces.

In general, it is better to run coolant when cutting any of the more challenging types of workpiece materials. Again, some of the best machining improvements documented resulting from high-pressure coolant delivery tooling systems have been with applications involving today’s exotic materials, such as titanium and nickel-based and cobalt-based alloys such as Nimonic C263, Inconel 718, Udimet 720 and Waspaloy. These materials are very gummy and ductile and thus require high levels of chip control attained by high-pressure coolant delivery tooling systems.

However the exotic alloys are not the only materials to show improvements when using high-pressure coolant delivery tooling systems. The automotive, marine, nuclear and food & beverage industries involve the use of ductile, long-chipping materials with rather low machinability. Austenitic and duplex stainless steel, low-carbon steels, and aluminium alloys, all show vast increases in metal removal rates, improvements to cutting data, chip control and surface finish, as well as reductions in production time.


As Seco Jetstream Tooling® eliminates chip evacuation issues, there is no need for operator interven-tion and therefore no disruption in production. Chip removal time is no longer part of the floor-to-floor time calculation. Additionally, the coolant inducer pivots of the Seco system allow machine operators to index a new cutting edge very quickly, guaranteeing that the cool¬ant is where it was before – in exactly the right place. To cool, or not to coolIt should be noted that some turning operations are better run dry without flood or directed high-pressure coolant. For instance, applications with intermittent or interrupted cutting conditions often generate thermal shock and benefit from running dry, as coolant can further magnify the negative effects of that thermal shock. In these cases, a high-pressure coolant tooling solution may circumvent the negative effects of coolant application.

Generally, continuous cutting conditions are typically best run with coolant. But where there are environmental issues, open-structure lathes or with certain types of steels, turning operations can be performed dry and with good results. Seco´s Duratomic® CVD-coated inserts with their effective heat resistance capabilities are well suited for this. Operations such grooving and parting-off, however, become more difficult when run dry mainly because of chip build up. In these operations, coolant – more specifically directed high-pressure coolant – can significantly improve performance.

Finishing operations often also should be run with coolant. Otherwise, shops can experience issues with component accuracy, as well as with surface finish quality. While most shops use coolant in up to 80% of their machining applications, some choose to run all of their operations dry e.g. for environmental reasons. Doing so requires closely monitoring and adjusting for heat generation within their machine tools, then keeping it in check to ensure component accuracy in terms of size and surface finishes. It is without doubt challenging and worth another tooling discussion, but fully possible today. Productivity and tool life reductions are significant when machining dry

compared to machining with coolant. The ideal systemWhen considering high-pressure coolant delivery tooling systems, manufacturers should evaluate systems not only based on their performance, but also on versatility and simplicity covering whole ranges of available coolant pressure levels in the machines. Systems should be easy to assemble and install into turning machines.

Ideal systems will also offer the choice of coolant being fed to a turning or grooving toolholder externally or internally. For feeding externally, systems such as Seco’s for shank toolholders, use hoses attached at the sides or underneath holders. Manufacturers can obtain a wide range of hose kits to easily connect the coolant supply at almost any position on a machine turret or toolblock. If the user no longer wishes to run the system, it can easily be removed and the machine restored back to its original coolant setup. For feeding internally, the system has channels within holders, as is the case when feeding coolant through the taper interface for Seco-Capto-style holders.

ConclusionNo matter what type of coolant system is incorporated, the key to effective chip control, tool life optimisation and increased production is first getting the coolant stream as close to the cutting zone as possible then directing it to the right place within the cutting zone. Jetstream Tooling® toolholders are a very minimal part of a machine investment in relation to the savings they provide in reduced cost per part. Any costs saved by purchasing a slightly lower priced low-pressure coolant system and tooling will be insignificant when compared to poor tool life and production losses due to machine downtime caused by chip build up.

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