1. /1 Customer project - table layshaft wheel (Machining of the friction welding seam) Material: 25MoCr4 Because of rising quantities the company Daimler AG is going to invest in a new machine tool for machining the table layshaft wheel. Currently the components are machined on a lathe with a driven unit. But in the rough turning prozess they have problems with the friction welding seam. During the machining a hard and solid ring springs up, which could damage insert and tool holder.

2. /2 Customer project - table layshaft wheel (Machining of the friction welding seam) » Slitting and Turning Material: 25MoCr4 Goal: The goal of this project was presenting the Daimler AG a concept to machine the friction welding seam with high reliability and productivity. Solution: Best possible solution: Turn-milling Alternative solution: Slitting and turning

3. /3 Customer project - table layshaft wheel (Starting situation) Cutting speed.: 300 m/min Feed per tooth (radial).: 0,15 mm Feed per tooth (axial).: 0,3 mm Cutting depth a p : 3 mm During the rough turning prozess a hard and solid ring springs up, which could damage insert and tool holder. Because of the ring chips also could not drop down and get caught up in the tool holder.

4. /4 Customer project - table layshaft wheel (Best possible solution - turn-milling) - no „ring“ is bulid up - short machining time (30 s) - high reliabilty (insert break, chips) - only one tool necessary For machining the friction welding seam on Mulit-Task-Machines, turn-milling is the best possible solution.

5. /5 Customer project - table layshaft wheel (Alternative solution - slitting and turning) For machining the table layshaft wheel on a lathe with driven unit, slitting and turning of the weldseam is an alternative solution. On big advantage is, that you do not need such a solid milling unit. But this version has two big disadvantages: - 33% longer machining time (42 s) - two tools are needed

6. /6 Customer project - table layshaft wheel

7. /7 Turn-milling with Coromill R390 (two cuts) toolR390-044C4-11MO60 insertR390-11T308M-PM depth of cuta p = 2 + 1,5 mm cutting speedv c = 235 m/min R.P.Mn = 1700 min -1 Radial feed: feed per toothf z = 0,09 mm feed ratev f = 600 mm/min Axial feed: feed per toothf z = 0,16 mm feed ratev f = 1100 mm/min

8. /8 Turn-milling with Coromill R390 (two cuts) Process reliabilitygood Process timeT = 49s Chip controlperfect Power consumptionP e =7,1 KW

9. /9 toolR390-044C4-11MO60 insertR390-11T308M-PM depth of cuta p = 3,5 mm cutting speedv c = 235 m/min R.P.Mn = 1700 min -1 Radial feed: feed per toothf z = 0,09 mm feed ratev f = 600 mm/min Axial feed: feed per toothf z = 0,16 mm feed ratev f = 1100 mm/min Turn-milling with Coromill R390 (one hit operation)

10. /10 Process reliabilitygood Process timeT = 30s Chip controlperfect Power consumptionP e =12 KW Turn-milling with Coromill R390 (one hit operation)

11. /11 Sloting of the welded seam and turning milling toolR300-020A25L-10L diameterD c = 20 mm number of toothZ= 2 milling insertR300-1032M-PM 1030 depth of cuta p = 3,5 mm cutting speedv c = 200 m/min feed per tooth (radial)f z = 0,04 mm feed per tooth (axial)f z = 0,16 mm turning toolN176.39-2525-12 turning insertRCMT-10T3M0-4225 depth of cuta p = 3 mm cutting speedv c = 300 m/min feed (radial)f n = 0,15 mm feed (axial)f n = 0,3 mm

12. /12 Sloting of the welded seam and turning Process reliabilitygood Process timeT = 42s Chip controlgood Power consumptionP e =3,1 KW P e =12 KW

13. /13 Summary The most effective solution is turn-milling as a one hit operation on a stable multi task turn milling machine. shortest process time high process reliability one tool for the roughing process If a classical lathe should be used for the operation slotting with a driven unit and then classical turning offers a reliable process too.