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REACH and RoHS Regulations Challenge Machinists Chip Breaking: Efficiently Machining Lead-Free Materials

Source: Press release | Translated by AI 3 min Reading Time

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Hartmetall-Werkzeugfabrik Paul Horn GmbH
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The alloying of lead in metallic materials positively affects the machining process. However, with the EU's REACH and RoHS regulations, the time for these easily machinable materials is over in many applications. The process-reliable machining must still succeed in the future. Paul Horn GmbH demonstrates with its wide tool portfolio a suitable solution for almost every application.

Horn has succeeded in developing a universal boring tool with sintered chip breaker geometry with the new Supermini type 105.(Image: Horn/Sauermann)
Horn has succeeded in developing a universal boring tool with sintered chip breaker geometry with the new Supermini type 105.
(Image: Horn/Sauermann)

The main problem in machining lead-free alloys, whether brass or free-cutting steel, is the often non-existent reliable chip breaking. But what exactly does the alloy component lead do?

Lead as an Alloying Element Forms Small "Nests"

In machining, the soft metal in the alloy creates predetermined breaking points, as lead forms small nests or inclusions in the alloy structure. These ensure good chip breaking and low cutting forces during machining. Furthermore, the heavy metal acts like a lubricant film, positively affecting tool wear.

Gallery

Switching to lead-free alloys was initially a challenge. The good machining properties of lead-alloyed materials were lost. Additionally, the wear on the cutting edge increases significantly.

Relief was provided in grooving and longitudinal turning by chip breaker geometries from the steel sector and specially laser-machined special geometries. Extensive studies show that chip-breaking geometries for steels with medium strength work very well, especially with lead-free materials.

Biggest Challenge in Internal Machining

In internal boring, adapted geometries also ensure reliable chip breaking. One of the biggest challenges in internal machining is long chips. These often occur during bore machining. They wrap around the tool, clog bores, or in the worst case, lead to tool breakage.

Previously, specially laser-cut or ground chip shaping geometries were used for this purpose. However, this was associated with a corresponding cost factor of the cutting insert. Horn has succeeded, with the new Supermini type 105 and the Mini type with I-geometry, in developing universal boring tools with sintered chip shaping geometry. In use, the tools offer high process reliability due to excellent chip control. The cutting edge geometry extends far into the corner radius of the cutting insert. This ensures chip control even with small feeds. The geometry can be used universally for different material groups and is suitable for internal, face, copy, and reverse turning.

I-geometry also for the "Mini" tool system

Paul Horn GmbH has also developed a chip breaker geometry for the "Mini" tool system types 108, 111, and 114. The sintered I-geometry is particularly aimed at machining materials with poor chip formation properties. It is suitable for copy turning, longitudinal turning, reverse turning, and face turning.

Particularly with small feeds in steel and stainless steels, the tool system with geometry shows its strengths in chip control. This leads to higher process stability and longer tool life in use. In developing the I-geometry, Horn also considered the machining of lead-free materials.

Since these materials pose a challenge due to their poorer chip formation in the future, the tool manufacturer offers cutting inserts with small corner radii starting from 0.05 mm for small lateral feeds. As a standard, corner radii from 0.05 mm to 0.2 mm are in stock.

The front-mounted screw-on inserts of the Mini type are among Horn's core products. The tool system is suitable for turning and milling applications. The precision tools have proven particularly effective in internal boring and grooving. With the low-vibration carbide tool holders, the inserts produce good surfaces even with longer overhangs and ensure high process reliability. The Mini system's portfolio offers inserts in various sizes for different internal diameters. Additionally, different geometries and substrates as well as CBN or diamond coatings are available.

(böh)

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