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News and press releases
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07/09/2009
C-Clamp from CERATIZIT, the clamping claw made of solid carbide
Automotive segment: increase from 1,500 to over 100,000 brake discs until the changing of the clamping claw is necessary |
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The CERATIZIT automotive segment will be presenting a world innovation at EMO: the first tool holder generation with a clamping claw made of solid carbide for the machining of brake discs.
A commonly known phenomenon when machining brake discs using ceramic and CBN is that the claw which holds the insert in its seat wears out early through erosion. Wear of the clamping claw is frequently the weak point in the process; until recently the only solution was to change the clamping claw at short intervals – meaning very frequently.
It does not fit in with the CERATIZIT philosophy of process optimization to consider the clamping claw as a mere wear part. “As pioneers in the field of innovative wear parts, having solved the cutting edge issues, we do not regard our task as fulfilled," says Gerhard Bailom, automotive segment manager at CERATIZIT. “We see the machining process as a whole and develop solutions for the optimization even when we have to choose unconventional ways to do so.”
And in fact, the CERATIZIT engineers opted for an unconventional approach when developing the claw made of a particularly well-suited carbide type which achieves extremely good results. While using the common claws made of steel it was possible to machine around 1,500 brake discs; the C-Clamp ensures that this figure rises to above 100,000 pieces. “The claw itself involves substantial costs, but there is a notable cost reduction resulting from the remarkably decreased machine downtime and enhanced process security," explains Bailom.
Extraordinary wear resistance and stability = increased tool life
In addition to extreme wear resistance C-Clamp offers a whole list of advantages. Thanks to its compact construction (short distance between screw and clamping point) it is characterized by a much higher stability than conventional claws, which enables an increase of between 10% and 50% in the durability of the inserts. The clamp’s stability is further improved thanks to the rigidity of the solid carbide which is considerably higher than the one of conventional claws. The compact construction together with its stability makes the C-Clamp perfectly suitable for special tools and double tool holders as well.
Another advantage offered by the C-Clamp is optimized handling, which automatically guarantees enthusiasm among the operators. The C-Clamp provides secure clamping of CBN and ceramic inserts types S, C, D and W with an inscribed circle of 9.52 to 12.7 mm and an insert thickness between 3.18 and 7.94 mm. Conventional solutions require 4 or even 5 different claws for this range, while the C-Clamp covers them all. This means that fewer spare parts are needed and the danger of mixing them up is eliminated.
ISO-W inserts are able to cover the same machining situations as C-inserts. They have 50% more cutting edges and are offered at a reduced price (about 25%) compared to C-inserts. Up to now the weak point was how to ensure secure clamping of W-inserts, mainly when there was higher stress. This problem has been totally eliminated thanks to the CERATIZIT C-Clamp. All C-applications can therefore be covered with W-inserts. In this context the use of insert WNNX080716TN-020D-C in ceramic grade CTN3105 is particularly interesting.
C-Clamp – the advantages at a glance:
- Most wear resistant claw available in the market
- Increased cutting speed and feed rates
- Maximum clamping force. The insert is reliably kept in its position during the entire tool life even under maximum stress.
- Claw and screw being one spare part means simplified spare part management
- Concentric ‘dimple’, positive lock,
high flexibility for special approach angle and special tool holders
- The special insert seat design ensures process security even when the inserts are worn
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World innovation at EMO: C-Clamp from CERATIZIT, the clamping claw made of solid carbide. The first turning tool holder generation for the machining of brake discs where the carbide insert has to be changed only after 100,000 brake discs compared to previously 1,500.
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“We see the machining process as a whole and develop solutions for the optimization even when we have to choose unconventional ways to do so.”
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