Since the company has been using the new Penta Cut 17 from Iscar, the processes involved in machining an aluminum piston have improved significantly. The all-round system for small components with five cutting edges enables longer tool life, saves tool costs and impresses with its user-friendly handling in the confined machine room.

Founded in 1977, Phiesel is an innovative turning shop that manufactures precision turned and milled parts from a wide range of materials for customers from various industries. 90 qualified employees at the Bad Münstereifel-Wald site in North Rhine-Westphalia produce quantities ranging from 20 to 6.5 million parts per year. The majority of customers come from the automotive industry, white goods, fittings and general mechanical engineering. "It is important to us to be broadly positioned and to maintain long-standing customer relationships. The requirements to produce economically and in high quality have increased significantly in recent years," says Managing Director Oliver Blankenheim, describing the market situation.

The company relies on the experience of its employees and modern machinery to produce dimensionally accurate precision parts, even in large quantities. This includes 45 metal-cutting processing machines and 25 systems for post-processing and surface finishing. Phiesel uses these to produce turned parts between four and 65 millimetres in diameter from bar stock and up to 250 millimetres as chucked parts. Various steels, aluminum, brass and also special materials such as various plastics are processed. Due to the high quality standards, Phiesel constantly carries out measurements and end-of-line tests during series production in order to minimize reworking. "However, we also attach great importance to keeping our machinery up to date with the latest technology," says Oliver Blankenheim. The company recently invested in a new multi-spindle automatic lathe with modern features.

Tantalizing prospect of a five-bladed tool

According to the Managing Director, trends have emerged in recent years. "Components are becoming more and more complex and the proportion of aluminum has increased significantly. These developments require flexible tools and machines," he outlines. In this context, the visit by Erik Hoffmann, Product Specialist Turning at ISCAR, to the office of Bernd Frantzen, Operations Manager at Phiesel, was well timed. "I presented our new Penta Cut 17 system and met with a positive response," he says. Bernd Frantzen recognized the potential of the ISCAR solution when machining an aluminium piston for a hydraulic cylinder. "We had previously been using a two-edged insert. The prospect of being able to use a five-edged tool was tempting," he explains. The plant manager then ran tests on the machine and was very satisfied with the results: a short time later, he switched to Penta Cut 17.

Iscar has developed Penta Cut 17 as part of its global Logiq product campaign. This provides users with an all-round system for a wide range of small parts applications on Swiss-type or multi-spindle machines. The five-edged inserts have a diameter of 17 millimetres. "The tool has a compact design with a small head dimension. This is particularly advantageous in multi-spindle machines and sliding headstock lathes, where space is often limited," explains Erik Hoffmann. Tools for miniature machining often only have two cutting edges. "With our solution, we have created an economical alternative in terms of price per cutting edge," he says.

Flexibility and precision in small parts processing

Penta Cut 17 is particularly suitable for the reliable machining of small turned parts up to a maximum cutting depth of four millimetres. ISCAR offers the tool in widths from 0.25 to 3.18 millimeters. Different geometries are available for parting off, grooving, recessing, back turning and threading. "The precision-ground cutting inserts have good repeat accuracy when changing cutting edges and therefore ensure high dimensional accuracy on the component without time-consuming readjustment," explains Erik Hoffmann.

Tool handling is simple. The clamping screw can be tightened from both sides of the holder in a user-friendly manner, which is particularly advantageous for machines with a small working area. The penta insert embedded at an angle of four degrees in the insert seat enables machining directly along the shoulder without any problems. Thanks to the ingenious insert seat, the remaining four cutting edges can continue to be used even if a cutting edge breaks. The highly positive flute also ensures a soft cut - an important advantage, especially for delicate and thin-walled components.

Significantly improved service life

The switch from the two- to the five-edge Penta Cut system has brought a whole range of advantages for Phiesel. The specialists cut a 1.5 millimeter wide and one millimeter deep groove on the seven millimeter long component on the new multi-spindle machine. "Interfering edges, such as with a competitor's double-edged tool, are a thing of the past," says Oliver Blankenheim happily. "We now achieve a favorable cutting edge price. Profitability has improved significantly," adds Bernd Frantzen. He is also very satisfied with the tool life. "The inserts work longer, the machine is well utilized. We no longer have to stop it so often to change tools."

Phiesel was also able to optimize process reliability. "The tool is very dimensionally stable and does not run. This is thanks to the compact insert seat," explains Frantzen. The chamfer, which enables smooth chip removal, also offers advantages. Bernd Frantzen awards good marks for the set-up times. "We can change the inserts quickly and easily in the machine. Access is possible from both sides, which simplifies handling."

"The service works very well"

Phiesel appreciates the cooperation with the ISCAR experts, with whom he has long-standing and trusting contacts. "We always get prompt help when problems arise. The service works very well," says Oliver Blankenheim. He praises the flow of information and always feels well informed about innovations. He attaches particular importance to this point. "As the products are becoming increasingly complex and the machining processes more demanding, the flexibility of the tools is becoming much more important. That's why it's important to know what's new from the manufacturers." Phiesel is already using Penta Cut 17 for three components - with room for improvement. Oliver Blankenheim: "It is quite conceivable that more will be added in the future."