working with tubular goods
a shop lacks machine tools capable of handling increased machining parameters, and/or work- pieces are of a scale or type that do not permit higher speeds, the new grades can provide tool life improvement of more than 20% while using the same cutting parameters.
Such was the case at a shop specializing in both standard and premium threads for the oil & gas industry. The shop beta-tested Seco’s new Duratomic TP0501 insert and experienced a 20% boost in rough blanking output for its threading operations. Rough blanking/rough turning quality dictates
SECO’s integrated approach resulted in a new group of three cutting tool grades that achieves a balance between hardness and toughness.
process optimization with higher parameters. These new grades represent an evolution and expansion of the Duratomic technology introduced by Seco Tools in 2007. The Duratomic CVD aluminum-oxide coating pro- cess manipulates coating components at an atomic level to achieve improved mechanical and thermal properties and enhance performance. The broad capabilities of the grades are a direct result of Seco’s Edge Intelligence Concept, which involves application and integration of the company’s exten- sive high-performance insert experience and knowledge.
More Speed and More Tool Life
The TP2501, TP1501 and TP0501 combine the benefi ts of advanced aluminum-oxide coatings with specially devel- oped compositions of the tools’ bulk substrates and cobalt- enriched zones. Modifi cations of those elements make the new grades both tougher and more wear resistant than their predecessors, across the board.
The shop beta-tested Seco’s new Duratomic TP0501 insert and experienced a 20% boost in rough blanking output for its threading operations.
Tests have shown that the new grades can provide
increases in cutting speeds of 20–30% while simultane- ously maintaining reliable tool life. On the other hand, when
thread size and fi nish. And for the test shop that generates up to 1000 premium-threaded part ends on a weekly basis, rough blanking is the one operation that can be manipulated—speeds and feeds—and optimized to shorten overall
threading cycle times. A Doubling of Output
During testing, the Duratomic insert provided over 400% longer tool life and allowed the shop to almost double its rough blanking feed rates. This is signifi cant because faster speeds and feeds mean the shop pumps out more parts per insert life span. In this case, the shop doubled its output. In addition to achieving the toughness and hardness bal- ance, the new Duratomic inserts incorporate an innovative used-edge detection technology. The insert surfaces feature an approximately 0.1-µm-thick chrome-colored PVD coating. Black aluminum oxide showing through the chrome-colored coating clearly identifi es a used insert edge and allows op- erators on busy shop fl oors to easily spot them. As part of its Edge Intelligence Concept for the devel- opment of the new inserts, Seco conducted a study that showed—even in shops with dedicated tool setup staff—as much as 10% of tool insert edges can go unused. This is because, without magnifi cation and time-consuming close examination, it can be diffi cult to tell if an edge has been used. The characteristic black color of high-performance aluminum-oxide coatings makes identifying used edges even more diffi cult. Furthermore, in shops where the operator is responsible for insert indexing and replacement, Seco’s survey sample in- dicated that as much as 30% of insert edges can go unused. The result can be expensive—a 25% rate of edge nonuti- lization means that the cost of one of every four inserts is
68 — Energy Manufacturing 2015
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