Quality times two: 100% increase in production achieved with cermet plates
Double the efficiency: The strategic use of cermet plates
When it comes to precision turned parts, Laubscher is a key player. For 175 years, the Swiss company based in Täuffelen has been supporting a wide range of customers from fields such as medical technology, the watchmaking industry and the automotive industry. These all require highly precise and often complex small and miniature parts as well as system components.
Customers have increasingly sophisticated demands when it comes to product quality, leading to a constant stream of new challenges. In the event of problems, costs can quickly skyrocket. With the support of Brütsch/Rüegger Tools, a new solution has been introduced into the metalworking industry that enables improved manufacturing quality and more efficient production at lower costs.
Your benefits using cermet plates:
- Achieve more accurate RA values
- Production capacity can be doubled
- Longer service life reduces frequency of replacement and costs
- More efficient processes thanks to durable cutting plates
- Consistent results even at high volumes
Do you want individual advice? Contact us at sales@brw.ch
Higher quality in demand
Remo Gerber, Head of Department in Metal Manufacturing at Laubscher, recalls: "We received a request from our client for increased surface quality of a turned part made of free-cutting steel." The RA value, which measures the roughness of metal turned parts in particular, was to be 1.6 µm from now on, instead of 3.2 µm as before — the roughness therefore needed to be halved.
It quickly became clear that the machining tool used previously, an ISO-standard carbide cutting plate, no longer met the new, stricter surface quality requirements.
The result was higher levels of tool wear and also an increase in waste. "We had to replace the cutting plate more frequently in order to achieve the required surface quality", reports Gerber. This led to increased tool costs and longer downtimes of the automatic machining unit during replacements, as well as more staff on duty. The entire manufacturing process slowed down and the result was unsatisfactory.
Information on RA value:
- The RA value is a unit of measurement that refers to the roughness of surfaces, particularly for metal parts produced by turning.
- A low RA value means a smoother surface, while a high RA value indicates a rough surface.
- The roughness can affect various properties of the metal part, such as friction, wear, corrosion resistance and the ability to absorb coatings.
- The RA value is usually expressed in micrometres (µm).
From old to new
In order to find a solution that worked, various machining plates were tested. In this particular case, an uncoated cermet plate proved to be the best solution. This is a plate that was previously used in metalworking for machining processes in the 1980s. However, it has since been displaced by other solutions.
Uncoated cermet plate
"But, newer models with coatings did not work in this case", explains Gerber. The coating deteriorated too quickly during the machining process and the required surface quality could no longer be obtained.
When looking for a supplier that offers cermet cutting plates with the required specifications, the solution was found at Brütsch/Rüegger Tools. "Our problem immediately became clear — we were actually looking for a tool that is hardly ever used in this material composition any more", reports Gerber. "We acquired some plates for testing and ultimately chose a Sandvik model that worked best."
Shows that the internal cooling runs through the centre of the shank and the connection is made at the rear instead of at the side to prevent collisions.
The holder with integrated cooling provides short cutting, extends the service life and improves surface quality.
Geometry used: PLATE DCMT11T308-UM type 5015 (CERMET coating).
Used on a multi-task machine from INDEX.
Double the volume in perfect quality
Thanks to the new plate, production capacity has been doubled as a result of the greater feed rate and higher cutting speeds than ever before. At the same time, setup and material costs have been reduced, because the CERMET cutting plate can be used to produce the required quality for longer. Since the cutting plate only needs to be replaced every 2 days, up to 4'000 pieces can be machined daily, compared to the previous peak of 2'000 turned parts.
The adjustments made by Brütsch/Rüegger Tools significantly reduced setup and material costs, which enabled twice the daily production output.
Conclusion: Positive across the board
A love for precision has been the driving force behind the Laubscher company since 1846
It only took a few days from initial contact to putting the new tools to use. "The advice and project support worked out very well", says Gerber. To this day, the new cutting plate has been put to use in a machining centre. Depending on utilisation, two to three machines at Laubscher Präzision AG in Täuffelen will be equipped with cermet plates from Brütsch/Rüegger Tools going forward.
About Laubscher
In 175 years, Laubscher Präzision AG has developed into the leading company in its industry. Today, Laubscher is considered a dependable partner for sophisticated precision parts and system components.
Complex parts are manufactured and made ready for installation using a wide range of production processes. The company has retained its character as an owner-managed family business all these years.
Profile
- Established: 1846
- Location: Täuffelen (BE), Switzerland
- Industry: Metalworking
- Employees: 240
- Machines: 500
- Production area: 22,500 m2
- Parts per year: 200 million
Interested in Laubscher products? Visit the company's website at laubscher.swiss
700 tonnes of raw materials such as stainless steel, brass, titanium and aluminium are processed annually, all in compliance with RoHS and REACH.
Laubscher Präzision AG supplies the highest-quality, precision miniature turned parts for medical technology, the watchmaking industry and more.
750,000 parts are produced every day
Thanks to individually adjustable parameters, the CNC machines enabled even more precise machining, including on more difficult materials