Professional Documents
Culture Documents
wheel machining
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Contents
Introduction
e-services
Complete aluminium machining
Competency in machining
System description - OvalFlex
System OvalFlex
System UTS/MaxiLock S
4-19
4
5
6-7
8-9
10
11
PCD inserts
MAC coolant supply
Grade overview
Grade description
Chip grooves
Applications
Adapters
External machining
Internal machining
Internal machining - profiles
Undercut
Hub machining
20-27
20
21
22
23
24
25
Mirror machining
Valve and bolt holes
Inserts
DC..
GX16..
GX24..
HubStar
RC..
VC..
26
27
28-37
28
29
30
31
32
33
XC..
X32..
EcoCut
ProfileMaster
Tools
OvalFlex
X32
MaxiLock S
MSS-Mono
UTS
12
13
14
15-16
17-19
34
35
36
37
38-68
38-50
51-53
54-60
61-64
65-68
Technical information
Special tools
Drilling tools
OvalFlex - characteristics, benefits
OvalFlex - axial clamping
OvalFlex - radial clamping
69
70-71
72
73
74
69-75
Cutting data, causes of wear
75
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suitable technology.
Competency in machining
External machining
Internal machining
Hub machining
Undercut
Mirror machining
Drilling
OvalFlex
System description
OvalFlex
OvalFlex is a modular tooling system for the machining of the entire aluminium wheel. Depending on the
respective insert, operators can machine both the external and internal profile, location face, hub profile
and visible outer surfaces. Furthermore, OvalFlex can flexibly be adapted for every kind of rim.
The tapered oval shape increases stability and performance capacity compared to conventional round
tools. In this way the aluminium wheel may be machined with high cutting parameters. In addition to axial
clamping CERATIZIT offers radial clamping.
OvalCoupling (OC)
Conventional clamping
Clearance
OvalCoupling (OC)
'OvalFlex Radial'
OvalFlex Radial guarantees high flexibility particularly in fields
where the aluminium wheel design and the dimension are
frequently modified. Radial clamping was in fact developed
by CERATIZIT to ensure that the tool change between the
individual machining steps takes only a short time and can be
carried out directly on the machine. Consequently, various tool
heads can be mounted onto the base adapters in a short time.
Within 8 seconds OvalFlex Radial is again ready for use.
OvalFlex HubStar
System description
HubStar
The most substantial time saving in
the field of aluminium wheel machining
is possible for hubs with diameters
> 60 mm. The rough diameter after
counterboring, stamping etc. is normally
between 40 and 45 mm. normally a
V-insert is used to bore the required
diameter in several stages (in some
cases back-boring is required, so a tool
change is necessary).
The HubStar program has been
designed to produce the necessary
diameter with one cut at a maximum
feed rate and to turn the location face
and profile of the hub with the same
tool. Time savings up to 65 seconds per
aluminium wheel are possible.
Conventional
machining
several cuts
OvalFlex HubStar
now in one cut only to the
required diameter
Division of cuts
Thanks to the special
positioning of the insert during
boring the cut and thus the
forces are divided in order to
make machining with minimum
vibration and maximum feed
rates possible.
Insert
The extremely stable HUB 1507QR-27 insert was specifically
developed for the hub machining of aluminium wheels. The insert
has suitable geometries and radii for every specific application:
Radius R .8 mm: machining of the cap seat
Radius R 1.2 mm: machining of the internal profile
Radius R 1.6 mm: turning of the location face
(higher feed rate possible)
R 1,2 mm
R 0,8 mm
R 1,6 mm
System OvalFlex
The OvalFlex system is tailor-made for aluminium wheel manufacture and its specific machines.
Optimized consistently from the cutting edge to the machine connection.
Tool heads
Adapters
X32..
VC..
HUB..
10
Adapters
System UTS/MaxiLock S
The tooling systems UTS and Maxilock S are tried and tested as well as characterized by high flexibility
and different machine types.
VC..
11
PCD inserts
12
Supply of compressed
air
Vortex tube
Exit of cold air
Turning tool
Recommended minimum coolant pressure: 6 bar
13
HW-K10
H216T / H10T
HW-K15
TSM20
HW-K15
Grade
designation
*Standard
designation
Cutting material
01
CTD4110
DP-K05
15
20
25
30
35
40
45
50
05
05
10
10
15
15
20
20
Main application
Extended application
Application range
14
05
10
Hard materials
25
25
H
Hard materials
HW-M10
H210T
Heat resistant
Heat resistant
HC-K20
Non ferrous
metals
CTP4120
50
Non ferrous
metals
45
40
Cast iron
HC-K15
35
30
Cast iron
CTP4115
25
20
Stainless
15
10
Stainless
HC-K10
05
01
Steel
*Standard
designation
AMZ
Application range
Steel
Grade
designation
Cutting material
Grade overview
Main application
Extended application
Grade description
Cast iron
AMZ
HC-K10
Composition:
Co 6.0%; WC balance
.
.
Grain size:
1 m
Hardness:
HV 1630
Toughness
Coating specification:
PVD
TiAIN; 2 - 4 m
4
Wear resistance
10
10
CTP4120
HC-K20
Properties, application:
Optimally suitable for aluminium and cast iron
Low tendency to adhesion
Composition:
Co 6.0%; WC balance
.
.
Grain size:
.8 m
Hardness:
HV 1820
Toughness
Layer specification:
PVD
TiB2; 4 m
4
Wear resistance
10
10
CTP4120
HC-K20
Composition:
Co 6.0%; WC balance
.
.
Grain size:
.8 m
Hardness:
HV 1820
Toughness
Layer specification:
PVD
TiB2; 4 m
4
Wear resistance
10
10
15
Grade description
Cast iron
H210T
HW-M10
HW-K10
Composition:
Co 6%; WC balance
.
.
Grain size:
.8 m (submicron grade)
Hardness:
HV 1850
Toughness
Wear resistance
10
10
H216T / H10T
HW-K15
Properties, application:
Ideal for heat resistant alloys, titanium, refractory metals
(W, Mo), aluminium, glass & carbon fibre reinforced
plastics
Low tendency to adhesion
Composition:
Co 6%; WC balance
.
.
Grain size:
1 m
Hardness:
HV30 1630
Toughness
Wear resistance
10
10
CTD4110
DP-K05
Composition:
Polycrystalline diamond (PCD)
.
.
Polycrystalline diamond:
~ 5 m
Toughness
16
Properties, application:
Optimally suitable for aluminium
High wear resistance
High heat resistance
Low tendency to adhesion
Wear resistance
10
10
Properties, application:
Maximum wear resistance and hardness
Low toughness
Chip grooves
-23P / -25P / -27 / -35
Application range:
CCGT 09T308FN-23P
ap: 0,5 - 4,5 mm
f: 0,05 - 0,3 mm
f [mm]
Application range:
CCGT 120408FN-25P
ap: 0,5 - 8,0 mm
f: 0,05 - 0,6 mm
f [mm]
Application range:
CCGT 1204..FN-27
ap: 1,0 - 10,0 mm
f: 0,1 - 0,75 mm
f [mm]
Application range:
X32-R4.00...-35
ap: 0,15 - 3,5 mm
f: 0,10 - 1,1 mm
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
17
Chip grooves
-F4 / -M4 / -F41 / -M41
Application range:
X32-R4.00...F4
ap: 0,1 - 3,0 mm
f: 0,1 - 0,6 mm
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
Application range:
X32-R4.00...M4
ap: 0,1 - 3,0 mm
f: 0,1 - 0,6 mm
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
Application range:
X32-R4.00...F41
ap: 0,15 - 1,5 mm
f: 0,15 - 0,5 mm
PCD segment
Optimized chip groove for
swarf control with small
depths of cut
Available cutting edge preparation: sharp (F), honed (E),
chamfered (T) according to
ISO designation system
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
Application range:
X32-R4.00...M41
ap: 0,20 - 3,0 mm
f: 0,15 - 0,7 mm
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
18
Chip grooves
-R41 / -U41
X32-R4.00...R41
ap: 0,20 - 4,0 mm
f: 0,15 - 0,8 mm
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
X32-R4.00...U41
ap: 0,15 - 3,0 mm
f: 0,15 - 0,7 mm
f [mm]
ap = larger depths of cut possible with other inserts (e.g.: XCGT to ap: 15 mm)
Geometry
sharp
-F41
-F4
-23
-M41
-25
-U41
M
-27
-35
-M4
-R41
19
Applications
Adapters
External machining
..40ER
..50ER
38
39
40
20
Applications
External machining
OvalFlex
0
22,5
35
41
27,5
35
44
35
45
Square shanks
SR..
SV..
32
54-55
E25..GX..
33
56-57
30
X32..
61
35
51-53
UTS
UT40..
33
65
21
Applications
Internal machining
OvalFlex
5
15
35
42
22,5
35
43
35
27,5
44
35
Square shanks
SR..
32
SV..
54-55
E25..GX..
33
56-57
Boring bars
A..SV22..
A..SV16..
33
58-59
33
MSS
15- GX24
27- GX24
30
30
63
UTS
UT40..SV..
33
22
66-67
64
60
30
61
45
45
35
46
Applications
Internal machining - profiles
OvalFlex
15
35
42
22,5
35
43
35
27,5
44
35
45
MSS
15- GX24
27- GX24
30
30
63
64
UTS
UT40..SV..
33
65
23
Applications
Undercut
OvalFlex
45
67,5
35
24
46
35
80
47
35
48
Applications
Hub machining
OvalFlex
HubStar
112,5
33
49
31
50
Boring bars
A..SV16..
33
58-59
A..SV22..
33
60
UTS
UT40..SV..
33
66-67
25
Applications
Mirror machining
OvalFlex
0
35
41
15
35
42
35
Square shanks
E25..GX..
30
61
UTS
UT40..E..
30
26
68
X32..
35
51-53
43
Applications
Valve and bolt holes
Drills
70-71
27
Inserts
DC..
-23P
-25P
-25Q
-27
0.20
0.40
0.20
0.40
0.80
DCGT 070202FN-25P
DCGT 070202FN-27
DCGT 070204FN-23P
DCGT 070204FN-25P
DCGT 070204FN-27
DCGT 11T302FN-25P
DCGT 11T302FN-27
DCGT 11T304FN-23P
DCGT 11T304FN-25P
DCGT 11T304FN-25Q
DCGT 11T304FL-25Q
DCGT 11T304FN-27
DCGT 11T304FR-25Q
DCGT 11T308FN-23P
DCGT 11T308FN-25P
DCGT 11T308FN-25Q
DCGT 11T308FL-25Q
DCGT 11T308FN-27
DCGT 11T308FR-25Q
H216T
Type,
description
H10T
H210T
L NR
r
[mm]
R
R
R
R
N
R
R
R
R
L
N
R
R
R
R
R
R
R
N
L
N
R
R
R
R
R
R
Steel
Stainless
Cast iron
Non ferrous metals
Heat resistant
r
r R R
R R R
R
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces DCGT 070202FN-25P H210T
28
l
[mm]
d
[mm]
s
[mm]
d1
[mm]
7.75
7.75
7.75
7.75
7.75
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
11.60
6.35
6.35
6.35
6.35
6.35
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
2.38
2.38
2.38
2.38
2.38
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
2.80
2.80
2.80
2.80
2.80
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
4.40
Inserts
GX16..
-27P
-27P
Type,
description
2.00
GX16-1E2.00N0.20-27P
GX16-2E3.00N0.30-27P
GX16-2R1.50N-27P
GX16-3E4.00N0.40-27P
GX16-3R2.00N-27P
GX16-3R2.50N-27P
GX16-4E6.00N0.50-27P
3.00
4.00
5.00
6.00
H216T
L NR
s
[mm]
l
[mm]
amax
[mm]
r
[mm]
R
R
R
R
R
R
R
16.0
16.0
16.0
16.0
16.0
16.0
16.0
2.0
2.5
1.5
3.0
2.0
2.5
3.5
0.20
0.30
1.50
0.40
2.00
2.50
0.50
Steel
Stainless
6
2,5
a max
a max
2,5
2,5
Heat resistant
Hard materials
R
R
2,5
Cast iron
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces GX16-1E2.00N0.20-27P H216T
29
Inserts
GX24..
-35PF
-27PF
-M4
3.00
4.00
H216T
L NR
r
[mm]
Type,
description
GX24-4R3.00N-25PF
GX24-4R3.00N-27PF
GX24-4R3.00N-M4
GX24-4R3.00TN-M4
GX24-5R4.00FN-M41
GX24-5R4.00N-35PF
GX24-5R4.00N-25PF
GX24-5R4.00EN-27DF
GX24-5R4.00N-27PF
GX24-5R4.00N-M4
GX24-5R4.00TN-M4
GX24-5R4.00TN-M41
CTD4110
-25PF
R
R
R
R
R
N
R
R
R
R
R
R
Steel
Stainless
Cast iron
Non ferrous metals
R
R R
Heat resistant
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces GX24-4R3.00N-25PF H216T
61
30
62-64
-M41
l
[mm]
s
[mm]
amax
[mm]
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
25.3
6.00
6.00
6.00
6.00
8.00
8.00
8.00
8.00
8.00
8.00
8.00
8.00
3.0
3.0
3.0
3.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
Inserts
HubStar
-27
Type,
description
15.88
HUB 1507QR-27
H216T
L NR
d
[mm]
s
[mm]
d1
[mm]
7.00
5.80
r 1,2
10
Steel
R
R
Heat resistant
Hard materials
r 1,2
Cast iron
Non ferrous metals
d1
Stainless
r 0,8
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 1 pieces HUB 1507QR-27 H216T
50
31
Inserts
RC..
-25P
-27
Type,
description
6.00
RCGT 0602MOFN-27
RCGT 0803MOFN-25P
RCMT 0803MOEN-25
RCGT 0803MOFN-27
RCGT 1003MOFN-27
8.00
10.00
H10T
H210T
L NR
d
[mm]
s
[mm]
d1
[mm]
2.38
3.18
3.18
3.18
3.18
2.80
3.40
3.40
3.40
4.00
R
R
R
R
Steel
Stainless
Cast iron
Non ferrous metals
Heat resistant
r
r R
R R
R
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces RCGT 0602MOFN-27 H10T
54-55
32
Inserts
VC..
-M4
-M41
0.40
0.80
1.20
1.60
3.00
Type,
description
VCGT 160404FN-25P
VCGT 160404FN-27
VCGT 160408FN-25P
VCGT 160408FN-27
VCUT 160408TN-M41
VCUT 160408FN-M41
VCUW 160408FN-M4
VCGT 160412FN-25P
VCGT 160412FN-27
VCUT 160412FN-M41
VCUT 160412TN-M41
VCUW 160412FN-M4
VCUW 160412TN-M4
VPGT 220516FN-25P
VPGT 220516FN-27
VPUT 220516FN-M41
VPUT 220516TN-M41
VPUW 220516FN-M4
VPUW 220516TN-M4
VCGT 220530FN-25P
VCGT 220530FN-27
VCUT 220530FN-M41
VCUT 220530TN-M41
VCUW 220530FN-M4
VCUW 220530TN-M4
H10T
H210T
L NR
r
[mm]
CTD4110
-27
CTP4115
-25P
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
l
[mm]
d
[mm]
s
[mm]
16.60
16.60
16.60
16.60
16.60
16.60
16.60
16.60
16.60
16.60
16.60
16.60
16.60
22.10
22.10
22.10
22.10
22.10
22.10
22.10
22.10
22.10
22.10
22.10
22.10
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
9.52
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
12.70
4.76
4.76
4.76
4.76
4.76
4.76
4.76
4.76
4.76
4.76
4.76
4.76
4.76
5.56
5.56
5.56
5.56
5.56
5.56
5.56
5.56
5.56
5.56
5.56
5.56
amax
[mm]
6.0
6.0
6.0
6.0
6.0
6.0
6.0
8.0
8.0
8.0
8.0
6.0
6.0
6.0
6.0
Steel
Heat resistant
amax
7
d1
r
r R
R R R R
R
35
Cast iron
Stainless
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces VCGT 160404FN-25P CTP4115
49
56-57
58-60
33
Inserts
XC..
-25P
Type,
description
3.20
XCGT 400632FN-25
H216T
L NR
r
[mm]
l
[mm]
d
[mm]
s
[mm]
d1
[mm]
45.90
19.66
7.50
5.60
Heat resistant
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 2 pieces XCGT 400632FN-25 H216T
34
R
R
d1
Cast iron
Non ferrous metals
Stainless
27
Steel
Inserts
X32..
-27P
-M41
3.00
4.00
1.60
2.00
H216T
L NR
r
[mm]
Type,
description
X32-R3.00N-27PF
X32-R3.00FN-M41
X32-R3.00TN-M41
X32-R4.00N-27P
X32-R4.00N-27PF
X32-R4.00EN-27DPF
X32-R4.00FN-M41
X32-R4.00TN-M41
X32-R1.60VN-23PF
X32-R1.60VN-27P
X32-R1.60VFN-M41
X32-R1.60VTN-M41
X32-R2.00VN-27P
X32-R2.00VFN-M41
X32-R2.00VTN-M41
CTD4110
-27P
CTP4115
-23PF
-M41
l
[mm]
s
[mm]
amax
[mm]
3.0
R R
6.00
R
R
R
R R
R
4.0
8.00
R
R
2.0
3.0
32.0
R
R R
5.0
R
R
3.0
5.0
R R
R
R
3.0
l
Steel
Stainless
Cast iron
Non ferrous metals
R
R R R
10
amax
Heat resistant
r
Hard materials
l
Main application
Extended application
International CERATIZIT range, for present availability see price list
amax
35
41-48
10
r
51-53
35
Inserts
EcoCut
-27P
-27Q
05
06
07
08
09
10
13
17
Type,
description
XCET 050202FN-27P
XCET 050202FN-27Q
XCET 050204FN-27P
XCET 050204FN-27Q
XCET 060202FN-27P
XCET 060202FN-27Q
XCET 060204FN-27P
XCET 060204FN-27Q
XCET 070304FN-27P
XCET 070304FN-27Q
XCET 080304FN-27P
XCET 080304FN-27Q
XCET 09T304FN-27P
XCET 09T304FN-27Q
XCET 10T304FN-27P
XCET 10T304FN-27Q
XCET 10T308FN-27P
XCET 10T308FN-27Q
XCET 130404FN-27P
XCET 130404FN-27Q
XCET 130408FN-27P
XCET 130408FN-27Q
XCET 170508FN-27P
XCET 170508FN-27Q
H216T
H210T
L NR
(l)
[mm]
l
[mm]
d
[mm]
5.00
5.80
6.00
6.50
7.00
7.60
8.00
8.50
9.00
9.60
10.00
10.60
12.50
13.50
16.00
17.50
R
R
R
R
R
R
R
R
R
R
R
N
R
R
R
R
R
R
R
R
R
R
R
R
R
Steel
Stainless
Cast iron
Non ferrous metals
Heat resistant
r
r R
R R
R
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces XCET 050202FN-27P H216T
36
s
[mm]
d1
[mm]
r
[mm]
2.10
2.10
2.10
2.10
2.38
2.38
2.38
2.38
3.18
3.18
3.18
3.18
3.97
3.97
3.97
3.97
3.97
3.97
4.76
4.76
4.76
4.76
5.56
5.56
2.25
2.25
2.25
2.25
2.50
2.50
2.50
2.50
2.80
2.80
3.40
3.40
3.40
3.40
4.40
4.40
4.40
4.40
5.30
5.30
5.30
5.30
5.30
5.30
0.20
0.20
0.40
0.40
0.20
0.20
0.40
0.40
0.40
0.40
0.40
0.40
0.40
0.40
0.40
0.40
0.80
0.80
0.40
0.40
0.80
0.80
0.80
0.80
Inserts
ProfileMaster
CTC1435
CTP2440
-M20
x
[mm]
R
L
R
L
R
L
R
L
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
2.00
2.00
2.00
2.00
2.50
2.50
3.00
3.00
Steel
R R
r R
r
r
r
Size
L NR
10
12
16
20
Type,
description
PM 10RG 201504-M20
PM 10LG 201504-M20
PM 12RG 201804-M20
PM 12LG 201804-M20
PM 16RG 252004-M20
PM 16LG 252004-M20
PM 20RG 302504-M20
PM 20LG 302504-M20
Stainless
Cast iron
Non ferrous metals
Heat resistant
y
[mm]
l
[mm]
s
[mm]
d1
[mm]
r
[mm]
1.50
1.50
1.80
1.80
2.00
2.00
2.50
2.50
5.00
5.00
6.00
6.00
8.00
8.00
10.00
10.00
2.10
2.10
2.30
2.30
2.80
2.80
3.80
3.80
2.10
2.10
2.50
2.50
3.40
3.40
4.10
4.10
0.40
0.40
0.40
0.40
0.40
0.40
0.40
0.40
Hard materials
Main application
Extended application
International CERATIZIT range, for present availability see price list
Ordering example: 10 pieces PM 10RG 201504-M20 CTP2440
37
OvalFlex
Tool holders, adapters
External machining
l2
l1
Type,
description
dA
d1
dA
[mm]
d1
[mm]
l1
[mm]
l2
[mm]
b
[mm]
h
[mm]
OC50-DIN69880-40ER
OC50-DIN69880-50ER
40
50
50
50
67
77
40
50
86.5
104
83
98
OC50R-DIN69880-40ER
OC50R-DIN69880-50ER
OC50R-DIN69880-40ER150
OC50R-DIN69880-50ER150
40
50
40
50
50
50
50
50
67
77
177
177
40
50
150
150
86.5
104
86.5
104
83
98
83
98
dA
[mm]
40
50
38
10002788/M16X1,5X6 SW8
10002788/M16X1,5X6 SW8
10002105/M16X59,5 SW8
10002105/M16X59,5 SW8
7896965/SW8-200K
7896965/SW8-200K
7730102/GREASE
7730102/GREASE
O-Ring 4,3-2,40
O-Ring 4,3-2,40
OvalFlex
Tool holders, adapters
Internal machining
d1
dA
l1
Type,
description
dA
[mm]
OC50-DIN69880-40IN110
OC50-DIN69880-40IN140
OC50-DIN69880-40IN175
OC50-DIN69880-50IN130
OC50-DIN69880-50IN170
40
40
40
50
50
OC50R-DIN69880-40IN110
OC50R-DIN69880-40IN140
OC50R-DIN69880-40IN175
OC50R-DIN69880-50IN130
OC50R-DIN69880-50IN170
40
40
40
50
50
d1
[mm]
l1
[mm]
D
[mm]
50
110
140
175
130
170
83
83
83
98
98
50
110
140
175
130
170
83
83
83
98
98
dA
[mm]
40
50
10002788/M16X1,5X6 SW8
10002788/M16X1,5X6 SW8
10002105/M16X59,5 SW8
10002105/M16X59,5 SW8
7896965/SW8-200K
7896965/SW8-200K
7730102/GREASE
7730102/GREASE
O-Ring 4,3-2,40
O-Ring 4,3-2,40
39
OvalFlex
Tool holders, adapters
OC 50
dA
d1
Internal machining
l1
Type,
description
dA
[mm]
d1
[mm]
l1
[mm]
OC50-DIN69880-40IL140
40
50
140
OC50R-DIN69880-40IL140
40
50
140
dA
[mm]
40
40
10002788/M16X1,5X6 SW8
10002105/M16X59,5 SW8
7896965/SW8-200K
7730102/GREASE
O-Ring 4,3-2,40
OvalFlex
Tool heads
0
dA
(OC50)
l2
l1
dA
[mm]
l1
[mm]
l2
[mm]
f
[mm]
OC50-X32R00E
OC50-X32L00E
R
L
50
70
50
30
X32...
OC50R-X32R00E
OC50R-X32L00E
R
L
50
70
50
30
X32...
X32...
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
35
41
OvalFlex
Tool heads
5
dA
(OC50)
l2
l1
dA
[mm]
l1
[mm]
l2
[mm]
f
[mm]
OC50-X32R05H
OC50-X32L05H
R
L
50
100
66
32
X32...
OC50R-X32R05H
OC50R-X32L05H
R
L
50
100
66
32
X32...
X32...
35
42
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
OvalFlex
Tool heads
15
15
f
dA
(OC50)
l2
l1
dA
[mm]
l1
[mm]
l2
[mm]
f
[mm]
OC50-X32R15H
OC50-X32L15H
R
L
50
100
80
36
X32...
OC50R-X32R15H
OC50R-X32L15H
R
L
50
100
80
36
X32...
X32...
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
35
43
OvalFlex
Tool heads
22,5
dA
(OC50)
f
22,5
l2
l1
dA
[mm]
l1
[mm]
l2
[mm]
f
[mm]
OC50-X32R22.5E
OC50-X32L22.5E
R
L
50
70
40
36
X32...
OC50R-X32R22.5E
OC50R-X32L22.5E
R
L
50
70
40
36
X32...
X32...
35
44
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
OvalFlex
Tool heads
27,5
dA
(OC50)
f
27,5
l2
l1
dA
[mm]
l1
[mm]
l2
[mm]
f
[mm]
OC50-X32R27.5F
OC50-X32L27.5F
R
L
50
80
60
40
X32...
OC50R-X32R27.5E
OC50R-X32L27.5E
R
L
50
70
50
40
X32...
X32...
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
35
45
OvalFlex
Tool heads
45
dA
(OC50)
45
l1
dA
[mm]
l1
[mm]
f
[mm]
OC50-X32R45E
OC50-X32L45E
R
L
50
70
55
X32...
OC50R-X32R45E
OC50R-X32L45E
R
L
50
70
55
X32...
X32...
35
46
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
OvalFlex
Tool heads
67
,5
dA
(OC50)
67,5
l1
dA
[mm]
l1
[mm]
f
[mm]
60
X32...
60
X32...
OC50-X32R67.5C
OC50-X32R67.5E
OC50-X32L67.5C
OC50-X32L67.5E
R
R
L
L
50
50
70
50
70
OC50R-X32R67.5E
OC50R-X32L67.5E
R
L
50
70
X32...
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
35
47
OvalFlex
Tool heads
80
dA
(OC50)
80
l1
dA
[mm]
l1
[mm]
f
[mm]
OC50-X32R80E
OC50-X32L80E
R
L
50
70
60
X32...
OC50R-X32R80E
OC50R-X32L80E
R
L
50
70
60
X32...
X32...
35
48
dA
[mm]
50
10001938/M5X20/T25
7883304/TORX T25 T
10002788/M16X1,5X6 SW8
OvalFlex
Hub tools
112,5
l2
dA
(OC50)
f2
49
f1
Dmin 50
l4
2,5
11
l3
l1
dA
[mm]
l1
[mm]
l2
[mm]
l3
[mm]
l4
[mm]
f
[mm]
f1
[mm]
OC50-D50R112.5H
50
100
77
82.0
59.0
21
28.0
VC.. 1604..
OC50R-D50R112.5H
50
100
77
82.0
59.0
21
28.0
VC.. 1604..
VC.. 1604..
dA
[mm]
50
7815102/M3,5X11,0/T15
7883301/KOMBI T15
33
49
OvalFlex
HubStar
HubStar
l2
dA
(OC50)
91
f1
l4
91
44
l3
l1
dA
[mm]
l1
[mm]
l2
[mm]
l3
[mm]
l4
[mm]
f
[mm]
f1
[mm]
OC50-HUB56R15K
OC50-HUB60R15K
OC50-HUB65R15K
50
125
112
82.7
82.7
86.7
91.0
91.0
95.0
28
30
32.5
26.5
27.5
30.0
HUB 1507...
OC50R-HUB56R15K
OC50R-HUB60R15K
OC50R-HUB65R15K
50
125
112
82.7
82.7
86.7
91.0
91.0
95.0
28
30
32.5
26.5
27.5
30.0
HUB 1507...
HUB 1507...
31
50
dA
[mm]
50
10001785/M5,0X10,8/T20
7897207/TORX T20 T
X32
Tool shanks
h
a
h2
h1
0 neutral
l3
Tmax
l2
l1
L NR
h
[mm]
25
32
Type,
description
X32N00-2525M
X32N00-3225P
h1
[mm]
h2
[mm]
b
[mm]
f
[mm]
l1
[mm]
l2
[mm]
l3
[mm]
a
[mm]
Tmax
[mm]
25
32
39.0
46.0
25
16.5
150
170
24
40.0
9.00
4.00
24
X32...
X32...
h
[mm]
25 - 32
10001938/M5X20/T25
7883304/TORX T25 T
35
51
X32
Tool shanks
h1
h2
0
l3
Tmax
l2
l1
Type,
description
X32R00-2525M
X32R00-3225P
X32L00-2525M
X32L00-3225P
R
L
h1
[mm]
h2
[mm]
25
32
25
32
39.0
46.0
39.0
46.0
b
[mm]
25
f
[mm]
l1
[mm]
25.5
150
170
150
170
l2
[mm]
24
X32...
35
52
h
[mm]
25 - 32
10001938/M5X20/T25
7883304/TORX T25 T
l3
[mm]
a
[mm]
Tmax
[mm]
40.0
9.00
4.00
9.00
4.00
24
X32...
X32
Tool shanks
h
a
h2
h1
22,5
22,5
l3
l1
Type,
description
X32R22.5-2525M
X32R22.5-3225P
X32L22.5-2525M
X32L22.5-3225P
R
L
h1
[mm]
h2
[mm]
25
32
25
32
39.0
46.0
39.0
46.0
b
[mm]
25
f
[mm]
l1
[mm]
32
150
170
150
170
l3
[mm]
a
[mm]
40.0
9.00
4.00
9.00
4.00
X32...
X32...
h
[mm]
25 - 32
10001938/M5X20/T25
7883304/TORX T25 T
35
53
MaxiLock S
Tool shanks
h1
SRDC...
l2
l1
L NR
h1
[mm]
25
Type,
description
SRDCN 2525 M06
SRDCN 2525 M08
SRDCN 2525 M10
h
[mm]
b
[mm]
l1
[mm]
l2
[mm]
f
[mm]
25
25
150
12.4
16.5
20.9
15.5
16.5
17.5
RC.. 0602..
RC.. 0803..
RC.. 1003..
h
RC.. 0602..
RC.. 0803..
RC.. 1003..
32
54
12 - 25 7815101/M2,5X6,0/T08
16 - 25 7883203/M3,0X7,3/T08
16 - 25 7815102/M3,5X11,0/T15
7883301/KOMBI T15
7817002/HM-U
7724106/TORX T08
7724106/TORX T08
Set 1-4
7815902/SORT
7883907/SORT
7883102/B M 3,5 7817902/SORT
MaxiLock S
Tool shanks
h1
SRGC...
l2
l1
25
h1
[mm]
Type,
description
SRGCR 2525 M06
SRGCR 2525 M08
SRGCR 2525 M10
SRGCL 2525 M06
SRGCL 2525 M08
SRGCL 2525 M10
l1
[mm]
l2
[mm]
150
18.5
19.6
19.6
18.5
19.6
19.6
R
25
L
f
[mm]
RC.. 0602..
RC.. 0803..
RC.. 1003..
RC.. 0602..
RC.. 0803..
RC.. 1003..
32
h
RC.. 0602..
RC.. 0803..
RC.. 1003..
12 - 25 7815101/M2,5X6,0/T08
16 - 25 7883203/M3,0X7,3/T08
16 - 25 7815102/M3,5X11,0/T15
7883301/KOMBI T15
7817002/HM-U
7724106/TORX T08
7724106/TORX T08
Set 1-4
7815902/SORT
7883907/SORT
7883102/B M 3,5 7817902/SORT
32
55
MaxiLock S
Tool shanks
10
7,
5
h1
SVHC...
l2
l1
Type,
description
SVHCR 2525 M16
SVHCR 2525 M22
SVHCR 3225 P16
SVHCR 3225 P22
SVHCL 2525 M16
SVHCL 2525 M22
SVHCL 3225 P16
SVHCL 3225 P22
h1
[mm]
l1
[mm]
l2
[mm]
25
25
32
32
25
25
32
32
150
150
170
170
150
150
170
170
20.0
21.9
20.0
21.9
20.0
21.9
20.0
21.9
f
[mm]
VC.. 1604..
VC.. 2205..
VC.. 1604..
VC.. 2205..
VC.. 1604..
VC.. 2205..
VC.. 1604..
VC.. 2205..
32
h
VC.. 1103..
VC.. 1604..
VC.. 2205..
33
56
12 - 20 7815101/M2,5X6,0/T08
20 - 25 7815102/M3,5X11,0/T15
12 - 32 7883202/M4,5X12/T15
7883301/KOMBI T15
7883301/KOMBI T15
7815002/HM-U
7815004/HM-U
7724106/TORX T08
Set 1-4
7815902/SORT
7883102/B M 3,5 7815901/SORT
7883101/B M 4,5 7883911/SORT
MaxiLock S
Tool shanks
h1
SVZC/SVZP...
10
l2
l1
h1
[mm]
Type,
description
SVZCR 2525 M16
SVZPR 2525 M22-16
SVZCL 2525 M16
SVZPL 2525 M22-16
l1
[mm]
l2
[mm]
150
27.3
32.3
27.3
32.3
R
25
L
f
[mm]
32
VC.. 1604..
VP.. 2205..
VC.. 1604..
VP.. 2205..
h
VC.. 1604..
VP.. 2205..
25
25
7815002/HM-U
7815005/HM-U
7883102/B M 3,5
7883101/B M 4,5
Set 1-4
7815901/SORT
7883912/SORT
33
57
MaxiLock S
Boring bars
dA
93
SVUC...
l2
l1
Type,
description
A32S SVUCR 16
A40T SVUCR 16
A32S SVUCL 16
A40T SVUCL 16
R
L
h
[mm]
l1
[mm]
l2
[mm]
f
[mm]
30
38
30
38
250
300
250
300
50
60
50
60
22
27
22
27
VC.. 1604..
VC.. 1604..
33
58
dA
32 - 40
7815102/M3,5X11,0/T15
7815002/HM-U
7883102/B M 3,5
7883301/KOMBI T15
1-4
7815901/SORT
MaxiLock S
Boring bars
dA
7,5
SVQC...
10
l2
l1
Type,
description
A32S SVQCR 16
A40T SVQCR 16
A32S SVQCL 16
A40T SVQCL 16
R
L
h
[mm]
l1
[mm]
l2
[mm]
f
[mm]
30
38
30
38
250
300
250
300
50
60
50
60
22
27
22
27
VC.. 1604..
VC.. 1604..
dA
32 - 40
7815102/M3,5X11,0/T15
7815002/HM-U
7883102/B M 3,5
7883301/KOMBI T15
1-4
7815901/SORT
33
59
MaxiLock S
SVXC/P
dA
Boring bars
13
h1
l2
l1
h
[mm]
Type,
description
A40S SVXCR 22
A40S SVXPR 22-16
A40S SVXCL 22
A40S SVXPL 22-16
l1
[mm]
l2
[mm]
f
[mm]
Dmin
[mm]
R
37
250
80
27
45
VC.. 2205..
VP.. 2205..
VC.. 2205..
VP.. 2205..
dA
[mm]
VC.. 2205..
VP.. 2205..
33
60
40
40
7883202/M4,5X12/T15
7883202/M4,5X12/T15
7724103/TORX T15
7724103/TORX T15
7896900/O-RING 40
7896900/O-RING 40
MSS-Mono
Tool shanks
Tmax
h1
MSS-Mono
l2
h
l1
Type,
description
E25R00-2525M-GX24-4
E25R00-2525M-GX24-5
E32R00-3232P-GX24-5
E25L00-2525M-GX24-4
E25L00-2525M-GX24-5
E32L00-3232P-GX24-5
h1
[mm]
b
[mm]
l1
[mm]
25
25
32
25
25
32
25
25
32
25
25
32
150
150
170
150
150
170
l2
[mm]
f
[mm]
42
25.9
25.9
33
25.9
25.9
33
Tmax
[mm]
24
GX24-4..
GX24-5..
GX24-5..
GX24-4..
GX24-5..
GX24-5..
h
[mm]
GX24-4..
GX24-5..
GX24-5..
25
25
32
7802180/A 2,2
7812301/SW 5
7802180/A 2,2
30
61
MSS-Mono
Boring bars
dA
l2
D min.
l3
l1
h
[mm]
Type,
description
I40R05-1.0D-GX24-4
I40L05-1.0D-GX24-4
I40R05-2.00D-GX24-5
I40L05-2.00D-GX24-5
R
L
R
L
37
l1
[mm]
l2
[mm]
230
40
40
80
80
f
[mm]
28
GX24-4..
GX24-4..
GX24-5..
GX24-5..
GX24-4..
GX24-5..
30
62
h
[mm]
37
37
7802180/A 2,2
7802180/A 2,2
7812301/SW 5
MSS-Mono
Boring bars
dA
l2
15
D min.
15
l3
l1
h
[mm]
Type,
description
I40R15-1.38D-GX24-5
I40R15-2.00D-GX24-5
I40L15-1.38D-GX24-5
I40L15-2.00D-GX24-5
l1
[mm]
l2
[mm]
f
[mm]
230
55
80
55
80
28
R
37
L
GX24-5..
GX24-5..
GX24-5..
h
[mm]
37
37
7812301/SW 5
7802180/A 2,2
7802180/A 2,2
30
63
MSS-Mono
Boring bars
dA
l2
f
Dmin.
27
27
,5
l3
l1
Type,
description
I40R27.5-1.38D-GX24-5
h
[mm]
l1
[mm]
l2
[mm]
f
[mm]
37
230
55
28
GX24-5..
GX24-5..
30
64
h
[mm]
37
7812301/SW 5
7802180/A 2,2
UTS
external
10
7.
5
dA
UT40-SVHCR
l1
Type,
description
UT40-SVHCR-16
UT40-SVHCL-16
R
L
l1
[mm]
f
[mm]
40
27
VC.. 1604..
VC.. 1604..
VC.. 1604..
1-4
7883102/B M 3,5
7883301/KOMBI T15
7815003/HM-U
7815102/M3,5X11,0/T15
7896900/O-RING 40
7815903/SORT
33
65
UTS
internal
dA
d2
93
Dmin.
SVUCR
l2
l1
Type,
description
UT40-32F-SVUCR-16
UT40-32F-SVUCL-16
R
L
l1
[mm]
l2
[mm]
Dmin
[mm]
f
[mm]
d2
[mm]
80
65
40
22
32
VC.. 1604..
VC.. 1604..
33
66
1-4
7883102/B M 3,5
7883301/KOMBI T15
7815003/HM-U
7815102/M3,5X11,0/T15
7896900/O-RING 40
7815903/SORT
UTS
internal
93
dA
d2
Dmin.
SVQCR
l2
l1
Type,
description
UT40-32F-SVQCR-16
UT40-32F-SVQCL-16
R
L
l1
[mm]
l2
[mm]
Dmin
[mm]
f
[mm]
d2
[mm]
80
65
40
22
32
VC.. 1604..
VC.. 1604..
VC.. 1103..
1-4
7883102/B M 3,5
7883301/KOMBI T15
7815003/HM-U
7815102/M3,5X11,0/T15
7815101/M2,5X6,0/T08
7896900/O-RING 40
7896900/O-RING 40
7815903/SORT
7815902/SORT
33
67
UTS
external
dA
UTS.. 0
Tmax
l1
Type,
description
UT40-E27D-R00-GX24-5
UT40-E27D-L00-GX24-5
R
L
l1
[mm]
f
[mm]
Tmax
[mm]
60
27
24
GX24-5..
GX24-5..
GX24-5..
30
68
7802180/A 2,2
7896904/SD 8X6
7896900/O-RING 40
69
Drilling tools
for the machining of aluminium wheels
Drilling tools with flexible application
Valve and bolt holes must be extremely precise and correspond to the specific dimensions. CERATIZIT
manufactures all drills with high profile precision and in every requested geometry. According to the
customer's request the tools may be produced in solid carbide, with or without internal coolant supply or
with inserts.
In addition CERATIZIT also manufactures tools for round holes and hub holes. The optimal solution for
these cases are cutting inserts from the systems EcoCut, EcoDrill or HFD, as they guarantee quick and
consistent rough drilling and finish-drilling.
70
Drilling tools
for valve and bolt holes
Solid carbide drilling tools
for the production of:
> valve holes
> bolt holes
The tools are specifically produced to customer requirements
with shank options to suit all standard adapters. Our tried and
tested carbide grade TSM20 is especially resistant to edge
chipping. This ensures extremely high process security during
application.
71
OvalFlex
Characteristics, benefits
Insert seat X32
> Notably larger and more stable insert
> Tapered top faces for optimum protection against pulling out
> Improved positioning of the insert thanks to 30 top faces
> Tapered central section provides larger insert width
32
tapered
R 6,4
R
30
30
tapered
Protection against
pulling out of the insert
Top faces
tapered
72
OvalFlex
Mounting with axial clamping
The tried and tested 'OvalFlex axial' is characterized by high stability. It represents the optimum solution
for applications which require a reduced number of tool changes.
3
2
1 M16x1,5
0,2 - 0,6 mm
50 Nm
7,5 Nm
The OvalFlex tool has been mounted completely and is now ready for use.
73
OvalFlex
Mounting with radial clamping
The tool change is carried out directly on the machine. Various tools can be quickly mounted and removed
from the adapter.
> Lock and then lightly unlock the tool
74
Work piece
material
Aluminium
wrought alloys
AI MG Si 1
Hardness
relative
machinability*
Cutting data,
causes of wear, wear types
HB
3-4
100
50-70
2-3
80
G - AI Si 1
Aluminium
cast alloys
G - AI Si 7
non hardened
H210T
H216T
CTD4110
CTP4115
vc
[m/min]
vc
[m/min]
400 - 2500
400 - 2800
G - AI Si 12
G - AI Si 7 Mg
Flank wear
Reasons:
> Cutting speed too high
> Carbide grade with insufficient wear resistance
> Incorrect feed rate
Remedies:
> Reduce cutting speed
> Select more wear resistant carbide grade
> Adapt feed rate to cutting speed and depth of cut (increase feed rate)
Cratering
Reasons:
> Cutting speed and / or feed rate too high
> Rake angle too shallow
> Grade with insufficient wear resistance
> Insufficient coolant supply
Remedies:
> Reduce cutting speed and / or feed rate
> Increase coolant quantity and / or pressure, optimize coolant supply
> Use grade with higher resistance to cratering
Built-up edge
Reasons:
> Cutting speed too low
> Rake angle too small
> Wrong cutting material
> Lack of cooling / lubrication
Remedies:
> Increase cutting speed
> Enlarge rake angle
> Apply TiN-coating
> Use emulsion with higher concentration
75
76
CERATIZIT worldwide
CERATIZIT worldwide
Production sites in the three big economic
areas with a worldwide network of CERATIZIT
sales and support engineers plus many
CERATIZIT distribution partners guarantee
customer vicinity.
CERATIZIT worldwide
Parent company in
Luxembourg
CERATIZIT Luxembourg Srl
Route de Holzem 101
L-8232 Mamer
Tel.:
+352 312 085-1
Fax:
+352 311 911
E-mail:
info@ceratizit.com
www.ceratizit.com
MA-PRO-0129-EN-12/12-SA
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129