Up to 50 percent higher cutting speeds

The hob cutter is made of a specially developed high-performance high-speed steel and enables up to 50 % higher cutting speeds compared to conventional PM-HSS tools, while at the same time ensuring high process reliability.

Carbide tools offer high performance, but are closely linked to critical raw materials such as tungsten and cobalt. For users, this means that tool costs and availability are currently difficult to calculate due to the tight raw material and procurement situation. This uncertainty can become an economic risk, particularly in series production. The focus is therefore shifting to cutting material concepts that combine high productivity with better cost and supply stability. One answer is the SpeedCore from Fette Werkzeugtechnik.

Process know-how as a decisive performance factor

In addition to the material, the process know-how also determines whether the SpeedCore fully exploits its technical and economic potential. Fette Werkzeugtechnik views machining as a complete system consisting of tool, workpiece, machine and machining strategy. The process parameters are individually adapted to the material, component geometry, machine kinematics and stability as well as the thermal and mechanical boundary conditions. "In contrast to generic parameter recommendations, the design at LMT Tools is specific to the material and application. The aim is to exploit the most economical process window in each case without jeopardizing process reliability," emphasizes Raphael Lienau, Managing Director of Fette Werkzeugtechnik GmbH & Co KG.

Processing time reduced by around 50

In an application for manufacturing a gear with module 9 for a planetary gear in mining machines, a SpeedCore milling cutter with Nanosphere 2.0 coating competed against a TiN-coated tool made of EMo5Co5, a cobalt-alloyed high-speed steel (HSS-E). The result: the machining time was reduced from 50.9 to 26.2 minutes. This corresponds to a reduction of around 50 %. The SpeedCore thus advances into performance ranges that were previously reserved for multi-part tools with carbide cutting edges. The one-piece design offers additional advantages in terms of accuracy, tool costs and effective number of teeth.

Efficient gear production

The SpeedCore is a high-performance and economical alternative for applications in which carbide is not always the optimal solution for reasons of cost, availability or process. The hob cutter also demonstrates how material science innovation and sound process expertise can help to meet current challenges such as cost pressure, raw material dependency and limited predictability in gear production. "The decisive strength lies not only in the material itself, but also in the ability to transfer it into application-specific processes in a targeted manner. It is this integration that creates real added value for the user," says Raphael Lienau.