When cutting a cap from Inconel, the noise level peaked at 93 decibels. Too much noise for the team at Schott's Technical Service Workshop. The solution: ISCAR's JETCROWN and a stable cutting tool from the LOGIQFGRIP series. This combination not only reduces the noise level to an acceptable level but also improves the surface quality of the component, reduces its manufacturing time, and increases tool life.
In its 140-year history, SCHOTT AG has evolved from a small glass factory in Germany to a globally operating specialty glass and materials technology company. The more than 17,000 employees in over 30 countries produce specialty glasses, glass ceramics, and polymers. These are used in the automotive industry, aerospace, optical industry, as well as in the communications and energy sectors.
In the 2022/2023 fiscal year, SCHOTT achieved a revenue of 2.3 billion euros. The company's headquarters is located in Mainz.
This is also where the Technical Service Workshop (TSW) is located. The 16-member team led by Oliver Fluhr, head of ceramic and special materials processing, manufactures ceramic and metallic components in small series starting from batch size one for internal use, such as repairing aggregates and glass melting tanks, but also for special orders. "For example, we were involved in the production of a 3D-printed disc for the center console of a concept car and have also supported mirrors for space telescopes," says Oliver Fluhr.
"But we are not only focused on exciting projects; we always try to optimize the processes in daily operations."
Focusing on employee well-being
Normally, in such cases, faster processing or higher output is the focus – but when cutting an Inconel cap, the situation was different. It belongs to the assembly of a heating system used for melting glass. The TSW regularly processes the Inconel component on the machine and produces between 50 and 150 pieces per year. The workshop crew cuts the part with a TANG-GRIP tool from the center of a 1,200-millimeter-long bar. It has a diameter of 48 millimeters.
"The problem was the noise level," explains Daniel Arnold, who works as a technician in the TSW. Measurements on the machine showed a typical sound pattern for processing the material – and a noise level of up to 93 decibels. "And that wears people out over time," says Oliver Fluhr. "It was clear that we had to do something about it."
While browsing the ISCAR catalog, Arnold discovered the 3D-printed JETCROWN for the TANGFGRIP tool holders from the LOGIQFGRIP series at the end of 2022. "It looked stable, and I thought it could help us with our problem," says the technician. "So I suggested to Oliver Fluhr to give the tool a chance." Following the motto "Trial makes wise," he contacted his long-time tool partner ISCAR and arranged a cutting test.
Stable tool with optimized cooling
The ISCAR team, consisting of Gerhard Heusel, Technical Consulting and Sales, and Michel Trill, Consulting and Sales, took on the challenge. "Inconel is not easy to machine; it is abrasive, expensive, and the user must compensate for quality fluctuations in the material," says Heusel. "For this task, a robust tool, the right cutting edge, and proper cooling are essential."
The ISCAR team put together a suitable package consisting of a LOGIQFGRIP holder TGTBQ 25R-D65-ECD-JHP, a TANGFGRIP cutting carrier TGAQ D65-3-4Z-ECD with four insert seats for TANGGRIP cutting inserts TAG N3J from the wear-resistant TiAlN-coated fine grain type IC808, and the JETCROWN.
"A major advantage of the LOGIQFGRIP tool holders is their robust construction," explains Michel Trill. "It allows for vibration-free cutting on the x-axis. With the JETCROWN, we literally crowned the tool." The additively manufactured component features flow-optimized coolant channels and cools the cutting insert from the chip and clearance surfaces. This reduces heat input into the material, protects the cutting edge, and improves chip removal. "And due to the very robust design, we have less vibration and therefore less noise," says Gerhard Heusel. With this solution, the ISCAR team in Mainz went into the race – and exceeded expectations.
Process-safe and quiet, 23 parts are produced per bar
"As you hear, you hear nothing," paraphrasing Shomaster legend Hans-Joachim Kuhlenkampff, describes Gerhard Heusel the situation during the test run. "The machine only whispered instead of singing while cutting." The display of the sound level meter showed 73 decibels, which is 20 decibels less than before. "We were amazed at how much the noise was reduced," says Daniel Arnold. "Even the coffee machine in the office is louder." The trial also revealed additional benefits:
"We not only significantly reduced the noise, but we were also able to achieve a visibly higher surface quality, increase the tool life, and reduce manufacturing time," says Oliver Fluhr. "That's a great bonus, even if the time gain for this component is not critical now."
The new solution went directly into practical use after testing. The SCHOTT team processes 23 parts per bar, after which the cutting edge is changed. "There could be more, but with such an expensive workpiece material, we don't want to take any risks," says Oliver Fluhr. He is not only more than satisfied with the tool, but also the reliable collaboration on equal footing with ISCAR has convinced him once again: "We are always in close contact. If we need support, I just call, and then Gerhard Heusel and Michel Trill stay on it until the solution is found," adds Oliver Fluhr.
"And I can always rely on honesty and fairness, knowing that selling at any cost is not the priority."
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