Process-reliable roughing in hardened tool steel

Since the partner classified the risk of an autonomous roughing process as critical due to a lack of empirical data, our focus was on validating tool life. Our approach was based on the assessment that with the correct geometry of the SHR family, hardened material can be roughed with process reliability over the target tool life.

We defined a machining strategy that makes mechanical loads controllable. To minimize risk, we first validated the process digitally using CAM simulation. Subsequently, the parameters were transferred to the machine, accompanied by our application engineering team for the fine-tuning of the cutting data on site.

Validation on the machine confirmed process stability. The required autonomous continuous operation of over 60 minutes is now realized reliably and reproducibly. We handed over the validated cutting data to the partner, enabling them to now perform hard machining even unattended.

By milling directly in the hardened material, the logistical effort of external heat treatment is completely eliminated. This results in an effective reduction of component lead time. With this optimized process, the manufacturer gains significant flexibility and can realize rush orders much more economically.