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Profi Lemaster - : Has Totally Redefi Ned The Machining Process
Profi Lemaster - : Has Totally Redefi Ned The Machining Process
With expertise and highly fle- in the three main economic tionship with our business partners
xible production facilities we areas and a worldwide sales results furthermore in long-term
strive to provide our busi- network of over 30 subsidiaries investments to strengthen
ness partners with direct and distribution partners ensure the sales organisations in the
competitive advantages in a quick response to customer various countries.
the field of hard materials for needs. In-house trainings and The CERATIZIT corporate value
tooling solutions and wear parts. seminars guarantee that both ‘The views and focus of our
Our dedication to hard material business partners and emplo- business partners matters’ is
matters creates intelligent solu- yees share the latest information a guiding principle for all 3,500
tions for tomorrow and time to on our product range. CERATIZIT employees world-
come. With 13 production plants The demand to improve the rela- wide.
Europe
• Austria
• Bulgaria
• Czech Republic
• France
• Germany
• Hungary
• Italy
• Luxembourg
• Netherlands
• Poland
• Switzerland
• Spain
• United Kingdom
North America
• USA Asia
• China
• India
• Japan
South America
• Brasil
3
4
Machining with ProfileMaster
Right-hand tool
Right-hand insert
Right-hand tool
Right-hand insert
5
ProfileMaster
Machining methods
2 Boring applications
Reduction of
– Tool changing times
– Reduced pre-setting and set-up times
– Less programming effort
“Masterfinish”
wiper effect
– Excellent surface quality Variable
– Shorter machining times
drilling diameter
Considerable tool
acquisition cost
savings
Reduced
stock-keeping
Produces a flat
costs
bottom hole
7
ProfileMaster
Productivity
Material costs
14 - 18 %
Increase in productivity:
(parts produced
+30%
per time unit) Increase in
productivity by
+30%
Due to improved utilization of the available
machine capacity considerable cost reduction
per workpiece becomes possible. results in
In this context ProfileMaster from CERATIZIT
makes a decisive contribution through:
reduction of
workpiece costs by -19%
- fewer tool changes -19%
- increase of cutting speed
- increase of feed rate
- increase of depth of cut
+30%
Increase of
tool life by
+30%
Increase of tool life:
8
ProfileMaster
Tools
Inserts
Nominal diameter [mm]
Cutting direction
Version ProfileMaster
Corner radius
Carbide grade
PM 25 R G 35 30 04 - M20 CTC1435
9
ProfileMaster Ø .394-.630 inch
Tools / radial application
1.5D (=l2)
2.25D (=l2)
inch
Type, L D
description (mm) d1 d2 l1 l2 l3 f A
PM 10R-1.5D-E (10) - 3.150 .590 -
R .500 .197 PM 10R..
PM 10R-2.25D-E .394 .630 2.821 .886 1.197
1/16“-27
PM 10L-1.5D-E (10) - 3.150 .590 -
L .500 .197 PM 10L..
PM 10L-2.25D-E .394 .630 2.821 .886 1.197
PM 12R-1.5D-E (12) - 3.543 .709 -
R .625 .236 PM 12R..
PM 12R-2.25D-E .472 .787 3.049 1.063 1.299
1/8“-27
PM 12L-1.5D-E (12) - 3.543 .709 -
L .625 .236 PM 12L..
PM 12L-2.25D-E .472 .787 3.049 1.063 1.299
PM 16R-1.5D-E (16) - 4.921 .945 -
R .750 .315 PM 16R..
PM 16R-2.25D-E .630 .984 3.832 1.417 1.831
1/8“-27
PM 16L-1.5D-E (16) - 4.921 .945 -
L .750 .315 PM 16L..
PM 16L-2.25D-E .630 .984 3.832 1.417 1.831
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts
Ordering example: 3 pieces PM 16R-2.25D
Spare parts / D
accessories (mm) inch 1 piece 1 piece
PM 10 ... (10) .394 10001230/M1,8X3,8/T06 7883305/TORX/T06
PM 12 ... (12) .472 7883215/M2,2X4,0/T07 7724105/TORX/T07
PM 16 ... (16) .630 7883214/M3,0X5,7/ T08 7724106/TORX/T08
Page 14 14 14
10
ProfileMaster Ø .787-1.260 inch
Tools / radial application
1.5D (=l2)
2.25D (=l2)
inch
Type, L D
description (mm) d1 d2 l1 l2 l3 f A
PM 20R-1.5D-E (20) - 5.906 1.181 -
R 1.000 .394 PM 20R..
PM 20R-2.25D-E .787 1.260 4.415 1.772 2.165
1/4“-18
PM 20L-1.5D-E (20) - 5.906 1.181 -
L 1.000 .394 PM 20L..
PM 20L-2.25D-E .787 1.260 4.415 1.772 2.165
PM 25R-1.5D-E (25) - 7.087 1.476 -
R 1.250 .492 PM 25R..
PM 25R-2.25D-E .984 1.575 5.233 2.217 2.858
1/4“-18
PM 25L-1.5D-E (25) - 7.087 1.476 -
L 1.250 .492 PM 25L..
PM 25L-2.25D-E .984 1.575 5.233 2.217 2.858
PM 32R-1.5D-E (32) - 7.874 1.890 -
R 1.500 .630 PM 32R..
PM 32R-2.25D-E 1.260 1.969 6.215 2.835 3.465
1/4“-18
PM 32L-1.5D-E (32) - 7.874 1.890 -
L 1.500 .630 PM 32L..
PM 32L-2.25D-E 1.260 1.969 6.215 2.835 3.465
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts
Ordering example: 3 pieces PM 20L-1.5D
Spare parts / D
accessories (mm) inch 1 piece 1 piece
PM 20 ... (20) .787 7722111/M3,5X7,2/T15 7724103/TORX/T15
PM 25 ... (25) .984 7783209/M3,5X8,6/T15 7724103/TORX/T15
PM 32 ... (32) 1.260 10001785/M5,0X10,8/T20 7724104/TORX/T20
Page 14 14 14
11
ProfileMaster Ø .630-.787 inch
Tools / axial application
1.5D (=l2)
2.25D (=l2)
= DNOM
DAXmin
Details see
page 32
inch
Type, L DNOM
description (mm) DAX d1 d2 l1 l2 l3 f A
PM 16R-1.5D-E (16) - 5.012 1.035 -
R .630-∞ .750 .224 PM 16L..
PM 16R-2.25D-E .630 .984 3.890 1.508 1.921
1/8“-27
PM 16L-1.5D-E (16) - 5.012 1.035 -
L .630-∞ .750 .224 PM 16R..
PM 16L-2.25D-E .630 .984 3.890 1.508 1.921
PM 20R-1.5D-E (20) - 6.016 1.291 -
R .787-∞ 1.000 .283 PM 20L..
PM 20R-2.25D-E .787 1.260 4.590 1.882 2.276
1/4“-18
PM 20L-1.5D-E (20) - 6.016 1.291 -
L .787-∞ 1.000 .283 PM 20R..
PM 20L-2.25D-E .787 1.260 4.590 1.882 2.276
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts
Ordering example: 3 pieces PM 16R-2.25D
Spare parts / D
accessories (mm) inch 1 piece 1 piece
PM 16 ... (16) .630 7883214/M3,0X5,7/T08 7724106/TORX/T08
PM 20 ... (20) .787 7722111/M3,5X7,2/T15 7724103/TORX/T15
PM 16.. PM 20..
Page 14 14
12
ProfileMaster Ø .984-1.260 inch
Tools / axial application
1.5D (= l2)
2.25D (= l2)
= DNOM
DAXmin
Details see
page 32
inch
Type, L DNOM
description (mm) DAX d1 d2 l1 l2 l3 f A
PM 25R-1.5D-E (25) - 7.217 1.606 -
R .984-∞ 1.250 .362 PM 25L..
PM 25R-2.25D-E .984 1.575 5.363 2.346 2.988
1/4“-18
PM 25L-1.5D-E (25) - 7.217 1.606 -
L .984-∞ 1.250 .362 PM 25R..
PM 25L-2.25D-E .984 1.575 5.363 2.346 2.988
PM 32R-1.5D-E (32) - 8.043 2.059 -
R 1.260-∞ 1.500 .461 PM 32L..
PM 32R-2.25D-E 1.260 1.969 6.384 3.004 3.634
1/4“-18
PM 32L-1.5D-E (32) - 8.043 2.059 -
L 1.260-∞ 1.500 .461 PM 32R..
PM 32L-2.25D-E 1.260 1.969 6.384 3.004 3.634
Supply details: Basic body fitted with 1 piece of clamping screw, without inserts
Ordering example: 3 pieces PM 25R-2.25D
Spare parts / D
accessories (mm) inch 1 piece 1 piece
PM 25 ... (25) .984 7883209/M3,5X8,6/T15 7724103/TORX/T15
PM 32 ... (32) 1.260 10001785/M5,0X10,8/T20 7724104/TORX/T20
PM 25.. PM 32..
Page 14 14
13
ProfileMaster
Inserts
Chip groove
inch
CTP2440
CTC1435
Type,
Size
x y
description (mm) (mm) l s d1 r
10 PM 10LG 201504-M20 M20 (2,0) .079 (1,5) .059 .197 .083 .083 .016
10 PM 10RG 201504-M20 M20 (2,0) .079 (1,5) .059 .197 .083 .083 .016
12 PM 12LG 201804-M20 M20 (2,0) .079 (1,8) .071 .236 .091 .098 .016
12 PM 12RG 201804-M20 M20 (2,0) .079 (1,8) .071 .236 .091 .098 .016
16 PM 16LG 252004-M20 M20 (2,5) .098 (2,0) .079 .315 .110 .134 .016
16 PM 16RG 252004-M20 M20 (2,5) .098 (2,0) .079 .315 .110 .134 .016
20 PM 20LG 302504-M20 M20 (3,0) .118 (2,5) .098 .394 .146 .157 .016
20 PM 20RG 302504-M20 M20 (3,0) .118 (2,5) .098 .394 .146 .157 .016
25 PM 25LG 353004-M20 M20 (3,5) .138 (3,0) .118 .492 .177 .173 .016
25 PM 25RG 353004-M20 M20 (3,5) .138 (3,0) .118 .492 .177 .173 .016
32 PM 32LG 404004-M20 M20 (4,0) .157 (4,0) .157 .630 .220 .236 .016
32 PM 32RG 404004-M20 M20 (4,0) .157 (4,0) .157 .630 .220 .236 0,4
Steel
Stainless
Cast iron
Non ferrous metals
Heat resistant
Hard materials
= Main application
= Extended application
= International CERATIZIT range, for present availability see price list
Ordering example: 20 pieces PM 10LG 201504-M20 CTC1435
PM -1.5D PM -2.25D
Drilling
feed (ipr)
.0063
.0055
.0047
.0039
.0031
.0024
.0016
.0008
Face turning
ap (inch)
.236
.197
.157
.118
.079
.039
feed (ipr)
15
ProfileMaster
Cutting depth / feed rate
Longitudinal turning
ap (inch)
.394
.354
.319
.276
.236
.197
.157
.118
.079
.039
ap (inch)
.319
.276
.236
.197
.157
.118
.079
.039
feed (ipr)
.0102
.0094
.0087
.0079
.0070
.0063
.0055
.0047
.0039
.0031
.0024
.0016
.0008
17
ProfileMaster
Depth of cut / feed rate
Longitudinal turning
ap (inch)
.236
.197
.157
.118
.079
.039
feed (ipr)
Face turning
ap (inch)
.236
.197
.157
.118
.079
.039
18
ProfileMaster
Feed rate
feed (ipr)
.0102
.0094
.0087
.0079
.0070
.0063
.0055
.0047
.0039
.0031
.0024
.0016
.0008
19
Cutting data
Grades / material
CTC
Hard-
VDI 3323
ness
1435
group
Workpiece vc
material Type of treatment / alloy HB [sfm]
annealed ≤ 0,15% C 1 125 459 - 918
Non alloyed steel annealed 0,15% - 0,45% C 2 150 - 250 328 - 656
tempered ≥ 0,45% C 3 300 262 - 590
annealed 6 180 328 - 656
Low alloyed steel tempered 7/8 250 - 300 262 - 525
A tempered 9 350 230 - 459
annealed 10 200 328 - 590
High alloyed steel
tempered 11 350 197 - 459
annealed ferritic 12 200 328 - 656
Corrosion resistant steel
tempered martensitic 13 325 262 - 492
annealed ferritic / martensitic 14 200 328 - 656
quenched austenitic 14 180 328 - 590
R Stainless steel
quenched duplex 14 230 - 260 –
hardened martensitic / austenitic 14 330 –
perlitic / ferritic 15 180 394 - 820
Grey cast iron
perlitic / martensitic 16 260 394 - 820
CTP
2440
vc
[sfm]
394 - 820
262 - 590
197 - 492
262 - 590
197 - 492
197 - 394
262 - 525
164 - 394
164 - 656
164 - 492
164 - 656
164 - 590
164 - 328
164 - 262
–
–
–
–
–
–
328 - 1640
328 - 984
328 - 1640
328 - 984
328 - 656
328 - 1640
328 - 1640
328 - 984
328- 984
262 - 590
197 - 492
328 - 820
66 - 164
66 - 131
49 - 82
33 - 66
33 - 66
164 - 394
98 - 164
–
–
–
–
21
MasterGuide
Material
Green: non ferrous metals Orange: heat resistant White: hard materials
and non metals alloys / titanium hardened steels (≥45 HRC),
Al wrought and Al cast alloys, Ni-/Co-base-alloys, chilled castings, hard cast
copper, copper alloys, non Ti-alloys irons
metal materials
22
MasterGuide
Application
● Main application
○ Extended application
Main application:
Medium machining of steel and cast iron
Extended application:
Medium machining of stainless steels
23
Grade description
Steel
CTC1435 Composition:
Co 9.5%; composite carbides 6.5%; WC rest
(P35, M30, K20)
Grain size: 1 - 2 µm
Hardness: HV 1400
Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B)
+ Al2O3 + Ti (C,N,B); 6 µm
0 2 4 6 8 10
Toughness:
Wear resistance:
CTP2440 Composition:
Co 9.5%; composite carbides 6.5%; WC rest
(P40, M35, K25)
Grain size: 1 - 2 µm
Hardness: HV 1400
Coating specification: PVD, TiAIN, 3 - 5 µm
0 2 4 6 8 10
Toughness:
Wear resistance:
24
Grade description
Stainless steel
CTC1435 Composition:
Co 9.5%; composite carbides 6.5%; WC rest
(P35, M30, K20)
Grain size: 1 - 2 µm
Hardness: HV 1400
Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B)
+ Al2O3 + Ti (C,N,B); 6 µm
0 2 4 6 8 10
Toughness:
Wear resistance:
CTP2440 Composition:
Co 9.5%; composite carbides 6.5%; WC rest
(P40, M35, K25)
Grain size: 1 - 2 µm
Hardness: HV 1400
Coating specification: PVD, TiAIN, 3 - 5 µm
0 2 4 6 8 10
Toughness:
Wear resistance:
25
Grade description
Cast iron
CTC1435 Composition:
Co 9.5%; composite carbides 6.5%; WC rest
(P35, M30, K20)
Grain size: 1 - 2 µm
Hardness: HV 1400
Coating specification: CVD, TiN + Ti (C,N) + Ti (N,B)
+ Al2O3 + Ti (C,N,B); 6 µm
0 2 4 6 8 10
Toughness:
Wear resistance:
CTP2440 Composition:
Co 9.5%; composite carbides 6.5%; WC rest
(P40, M35, K25)
Grain size: 1 - 2 µm
Hardness: HV 1400
Coating specification: PVD, TiAIN, 3 - 5 µm
0 2 4 6 8 10
Toughness:
Wear resistance:
26
Grade overview
Non ferrous
Stainless
materials
materials
Cast iron
resistant
05 15 25 35 45
metals
Steel
Hard
Heat
01 10 20 30 40 50
HC-P35
CTC1435 HC-M30
HC-K20
HC-P40
CTP2440 HC-M35
HC-K25
27
ProfileMaster
Problems / corrective measures
Type of problem
Type of wear Workpiece Chip control
problems
Surface quality
Built-up edges
Edge chipping
Flank wear
Vibrations
Corrective
measures
Cutting values
Cutting speed
Feed rate
Selection of inserts
Wear resistance
Cutting material
Toughness
Clamping of tool
Clamping of workpiece
General criteria
Overhang
Tip height
Cooling lubricant
28
ProfileMaster
Application recommendations
Through hole
29
ProfileMaster
Application recommendations
Off-centre drilling
Due to the special construction of ProfileMaster tools and inserts off-centre drilling is possible. Thus desired devations
from the tool‘s nominal diameter can be obtained (see table below).
Situation: Solution:
In case of insufficient movement of the machine across the Use a right-hand
centre line the external diameter can not be machined with ProfileMaster tool
the same tool.
Maximum movement
across centre line
30
ProfileMaster
Coolant supply / “Masterfinish” effect
Coolant supply
1 3
“Masterfinish” effect
feed (ipr)
vc = 492 sfm ap = .0394 inch
31
ProfileMaster
Application recommendations
= DNOM
DAXmin
(16) .630 .630 ∞
(20) .787 .787 ∞
(25) .984 .984 ∞
(32) 1.260 1.260 ∞
Situation Situation
DAX >= DNom DAX < DNom
DAXmin = DNom
DAXmax = ∞
32
ProfileMaster
Machining examples 1 + 2
Criteria:
> Problems due to lack of turret positions
> Optimisation of machining time
Cutting data:
vc [sfm] 492
ap [inch] .0394
f [inch/rev.] .0059
Technical data:
Criteria:
> Increase in productivity
> Insufficient quality of groove surface
Technical data:
33
34
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