IndIvIdual SolutIonS engIneered for you

Component engIneered toolIng

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from ConCeptIon to realISatIon of Complete CuttIng tool SolutIonS

SeCo expandIng your engIneerIng CapabIlItIeS

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When you engage with Seco, you experience a true partnership based on trust, respect and open communication. The comprehensive solutions you receive result from our 80 years of experience in providing products and services for milling, turning, holemaking and tool holding applications. Our focus extends far beyond the products we provide, as we work to deve-lop innovative, customised manufacturing processes tailored to your unique components.

Seco CET (Component Engineered Tooling) works closely with your team and relevant providers of complementary equipment, coordinating the planning, creation and implementation of solutions built around your specific needs. Global in scope, but local in execution, CET brings proven methodologies and a world of expertise to optimising your new and existing applications.

About Seco ..........................................................................................................3Seco’s Industry solutions ....................................................................................4Component Engineered Tooling .......................................................................6Your challenges - your customised solution ......................................................8Seco’s CET Support .........................................................................................10Aerospace - CET Solution ................................................................................14Power Generation - CET Solution ...................................................................15Automotive - CET Solution ..............................................................................16Medical - CET Solution ....................................................................................17Oil & Gas - CET Solution .................................................................................18Find out more about Seco ...............................................................................19

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InduStry SolutIonS -InSpIred by SeCo,deSIgned for youSeco works closely with manufacturers in major industries to create and provide solutions that increase productivity and bolster profitability. With more than 5,000 team members in over 45 countries, we offer a globally networked resource dedicated to solving your challenges and supporting your operations. Through cooperative partnerships with manufacturers and entities around the world, we monitor trends, identify challenges and deve-lop solutions that overcome the industry’s most demanding applications.

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automotIveToday’s automotive applications range from prototyping new engine technolo-gies to large production runs. Seco’s extensive experience in the segment will strengthen your business wherever you fall on the spectrum. We stay at the fore-front of industry trends, always prepared for your newest machining challenges.

aeroSpaCeServing the aerospace industry means constantly adapting to changing trends and challenging materials, such as exotic titanium alloys and newly developed compo-sites. Seco’s constant research and metal cutting innovations keep you ahead of the curve, highly productive and able to sustain your competitive advantage.

power generatIonPopulation growth and increasing consumption make manufacturing for the ener-gy industry a smart move. When you‘re facing the challenges of new materials and component designs, our constant innovations in product and processes allow you to produce more complex and demanding parts.

wInd powerSeco’s comprehensive innovations for machining large wind power components can maximise your success in serving this rapidly growing segment. Our engineers understand the challenges of working with long overhangs and high grade steels, resulting in tools and processes that expand your operations’ potential to the maximum.

medICalManufacturers of medical components face challenging materials, highprecision and surface finish requirements. Through our expertise in medical applications as well as innovative standard and custom tools, Seco empowersyou to achieve strict quality, optimised productivity and high profitability.

oIl & gaSStaying competitive in the oil & gas industry can require the ability to productively undertake heavy duty machining operations. Seco offers tools to optimise your toughest milling, turning and threading applications, and provides the expertise that empowers you to get the most out of them.

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totallyengIneered SolutIonS

SeCo Cet unIque engIneerIng ServICe – deSIgned for you

We understand that your re- quirements are unique, demand- ing and require more than an off-the-shelf solution. CET adopts an approach tailored to your operations, whether its simple process optimisation of your component or creating a complex, comprehensive turnkey package. We provide a single point of support through-out the lifetime of your project. This contact draws upon the full resources of Seco’s glo-bal expertise in tooling and process solutions, while also coordinating with relevant technology partners to ensure you achieve optimum producti-vity and profitability.

Our CET engineers recognise the importance of understand-ing the effects of every element within your manufacturing processes. The machine tool, workholding, tooling and CAM strategy all affect the produc-tivity, security and cost of your components. Because of this, we take a comprehensive ap-proach, whether we are reengi-neering an existing workpiece or starting with a blank sheet de-veloping a new process together with a machine tool supplier.

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optImISIng your return on InveStment

unloCkIng the potentIal of your maChIne toolS

Purchasing a machine tool reflects a major investment for your organisation. When undertaking this process, Seco partners with you and your choice of machinery supplier to ensure you get the highest possible performance and return from your new equip-ment. By helping you achieve 100% utilisation from day one, we contribute to minimising your payback period and im-proving your cost performance.We have established close rela-

tionships with major machine tool suppliers establishing trust and cooperative partnerships over the years. These companies recognise the value we provide both in product excellence and technical competence. When you involve us at the beginning of the machine purchasing pro-cess, our collaboration with the machine tool builder ensures optimisation at every stage. With a total commitment to your success, we provide a simple, yet comprehensive approach to integrating new equipment.

Component engIneered toolIng

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SolutIonS InSpIred by ConquerIngyour ChallengeS

our expertISe• Dedicated professional project

support from the Seco team• Access to our complete tool-

ing solutions• Coordination and integration

of all suppliers• Global resources focused on

your success

the ChallengeS you faCe • Identifying trustworthy part-

ners who share your passion and vision

• Staying up-to-date with the latest technology

• Finding providers who un-derstand the importance of improving your manufactur-ing processes

• Selecting partners who can overcome restraints and opti-mise capital equipment

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red CreatIng your CuStomISed SolutIonanalySIS• Understanding your goals and individual requirements• Identifying and gathering with your team all relevant information• Establishing communications channels and key contacts

ConCeptIon• Identifying potential processes with relevant tools• Evaluating productivity, cost and performance• Agreeing on concept modules• Designing a solution based on your unique requirements

delIvery• Realising a complete technical proposal based around your needs• Identifying a breakdown of required tooling and justiication of

associated costs• Initiating the manufacture of custom tools

ImplementatIon• Implementing the new technology• Providing support and training on new methods• Documenting the change

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Cet – a ServICe totally dedICated to addreSS your needS:

• Increase manufacturing productivity

• Manage your supply chain• Reduce your costs• Manage with more limited

resource while never far away from Seco’s vast knowledge base

your team IS larger than you thInk

loCal Cet Support ConneCted to a global network

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traInIng & Support Offering high level education and support around the intro-duction of a new process

SeCo teChnICal CentreS Component testing in our high-tech machining facilities

doCumented CoSt analySIS Identifying and reducing your high cost processes with our powerful PCA software

Component CoSt management Analysing and managing your tooling and manufacturing expenditure

CoordInatIon of relevantteChnology partnerS

Providing you with a totally inte-grated manufacturing solution

underStandIng your manufaCturIng needS

Engaging with you to truly iden-tify your requirements

CuttIng tool expertISe Enabling the best cutting tool solutions for your processes

maChIne tool vendor CooperatIon

Optimising the pay back on your investment

dedICated Cet Support One point of contact for the duration of a project

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the CommItment and expertISe you reCeIve from SeCo

a global network of expertSThe Seco Strategic Engineering Group offers a global support network comprised of inter-national component specialists with extensive expertise in specific industry segments. This team works with your locally based Seco application experts to bring you truly world class solutions and so no matter where in the world you are, you are never far away from Seco’s vast knowledge base.

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SeCo global teChnICal CentreSDedicated to component testing and transferring our expertise to your team members, our Technical Centres provide valuable machining services and a variety of valuable learning events. From product launches to segment-specific events and technical education courses, these facilities provide immense value in keeping your workforce competitive. Additionally, we use the Technical Centres inter-nally, bringing together global providers from diverse fields to share information and discover best practices that can improve your business.

doCumented proCeSS optImISatIon

Through the Seco TechnicalMedia Platform, we can trans-form your cutting data intoreports that demonstrate actualcost and time savings. Toolssuch as our Productivity andCost Analysis (PCA) softwareallow us to benchmark existingprocesses and compare them toprojected and realised savingsfrom proposed improvements.These tools are fully scalable,from assessing a single machin-ing application to evaluatingworkflows throughout yourfacility.

CuStomISed toolIng SolutIonSWhen your application de-mands more than a standard product, Seco Custom Tooling will create a tailor-made solu-tion that addresses your unique needs. Our team offers com-plete support, analysing your application and developing the perfect tool to optimise it. We maintain 19 state-of-the-art production facilities worldwide, allowing Seco Custom Tooling to always be available to make your challenge our priority.

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aeroSpaCe

CetSolutIonChallengeDevelop a full turnkey solution by partnering with the machine tool builder and workholding provider. key ConSIderatIonS• Develop customer and

component knowledge• Cooperate with strategic

partners• Utilise CET global network• Employ the assistance of

segment specialist• Oversee roll out to customer

subsidiaries

reSultS• Minimised machine pass

off time • Achieved roll out to full

production across customer’s global sites

• Provided customer with complete confidence in Seco as a global provider

CaSe – reamIng guIde vane holeS wIth SeCo preCImaSter™

Material: M152

Coolant: Flood Coolant

Operation: Ream Holes

Criterion: Number of holes

Fixturing: Bespoke

Tool: PM08-14500-20N1

Insert 1: PM60-16H7-EB45

Cutting vc f L D

data Metric 40 m/min 0.25 mm/rev 42 mm 14.5 mm

Inch 131 sf/min 0.0100” ipr 1.653” 0.571”

results 10 times quicker than previous method.

CaSe – drIllIng flange holeS wIthSeCo feedmaxMaterial: Inconel 718

Coolant: Through coolant 80 bar

Operation: Drill Flange Holes

Criterion: Number of holes

Fixturing: Bespoke

Tool: SD203A-10.0-31-10R1-M

Insert 1:

Cutting vc f L D

data Metric 31 m/min 0.076 mm/rev 10 mm 6.35 mm

Inch 100 sf/min 0.003” ipr 0.393” 0.250”

results minimum exit burr, 25% more tool

life than competitor.

blade – tapered ball noSe mIllIng Cutter

Material: X22CrMoV12-1 Coolant: Emulsion

Operation: Semi-inishing milling

Criterion: Wear vb = 0.2 mm (0.008”)

Fixturing: Chuck - tailstock

Tool: R218-24-25R100.0-048-09.2A

Insert 1/2: R218.20-100ER-M05, F40M | XOMX090308TR-ME06, F40M

Cutting vc fz ap

data Metric 270 m/min 0.233 mm/tooth 1-30 mm

Inch 885 sf/min 0.0092”/tooth 0.04-1.8”

Cutting ae vf

data Metric 0.5 mm 2000 mm/min

Inch 0.02” 79”/min

results extended tool life, reduced tool cost and eliminated

regrinding operations compared to existing solid

carbide cutter solution.

blade – power 4™ Copy mIllIngMaterial: X12CrNiMoV12-3

Coolant: No

Operation: Blade airfoil roughing milling

Criterion: Tool life must reach the end of component

Fixturing: Special

Tool: R220.24-0052-12.5A

Insert 1: ROHT1204M0-M12, MS2500

Cutting vc fz ap

data Metric 350 m/min 0.4 mm/tooth 3 mm

Inch 1150 sf/min 0.016”/tooth 0.118”

Cutting ae vf

data Metric 12 mm 4400 mm/min

Inch 0.472” 173”/min

results higher chip removal rate.

powergeneratIon

CetSolutIonChallengeFurther develop a machining process on an existing machine tool to meet a significant in- crease in component demand. key ConSIderatIonS• Deliver a stable, dependable

process• Signiicantly reduce manu-

facturing times • Reduce tool spend per

component• Customer preference for

a proven solution

reSultS• 40% reduction in cycle time• Reduced inventory, due to

reduced number of tools• Further opportunities realised

as customer standardises machining process

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automotIve

CetSolutIon

SteerIng knuCkle – r335.19 dISC mIllIng CutterMaterial: Nodular cast iron (GGG) (SMG 13)

Coolant: Water soluble oil

Operation: Control arm connection slotting

Criterion: Tool life

Fixturing: Hydraulic clamping ixtureTool: Disc milling cutter R335.19 160.04 40-9

Insert 1: SNHQ110204TR4-M07, F30M

Cutting vc fz ap

Data Metric 150 m/min 0.14 mm/tooth 4 mm

Inch 490 sf/min 0.0055”/tooth 0.157”

Cutting ae z k

Data Metric 16 mm 18 9

Inch 0.630” 18 9

results tool life = 5000 pcs. / reduced slot shrinking effect

due to low cutting forces.

SteerIng knuCkle – CuStom xfIx™ multI-tooth reamerMaterial: Nodular cast iron (GGG) (SMG 13)

Coolant: Water soluble oil

Operation: Ball bearing bore inishingCriterion: Tolerance H6, cylindricity = 5µ, surface inish Ra = 1Fixturing: Hydraulic clamping ixtureTool: Multi-tooth XFIX reamer Ø 78 mm and chamfer

Insert 1/2: LNEG1003-EB45-06, RX1500 / SCGX060204-P2, T2000D

Cutting vc f

Data Metric 120 m/min 0.15 mm/tooth

Inch 395 sf/min 0.006”/tooth

Cutting ap ae z k

Data Metric 0.2 mm (0.4 mm to Ø) stroke = 35 mm 5 5

Inch 0.008” (0.016” to Ø) stroke = 1.378” 5 5

results tool life = 3000 pcs. per edge

25% increase to tool life.

ChallengeAccommodate an increase in vo-lume by optimising the existing process to reduce cycle time by at least 15%. key ConSIderatIonS• Utilise existing machinery• Deliver a secure and stable

solution• Reduce non-cutting time of

the process• Develop and manufacture

customised tooling• Improve component quality

reSultS• Documented 20% reduction

in cycle time• Improvement to component

quality through optimised tooling

• Reduced tool inventory• Increased customer capacity

without requiring equipment investment

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aCetabular Cup - SeCo turnIng grade th1000

Stem - SeCo feedmax™ CuStom drIll & Chamfer

Material: Cobalt chrome

Coolant: Oil

Operation: Turn spherical outside diameter

Criterion: Increase tool life

Fixturing: Bespoke

Tool: PWLNR2020K08

Insert 1: WNMG080408-MF2 TH1000

Cutting vc f ap

data Metric 30 m/min 0.15 mm/rev 0.5 mm

Inch 100 sf/min 0.006” ipr 0.02”

results tripled tool life and provided a 35% reduction to cycle

time.

Material: Titanium alloy

Coolant: Water soluble ‚through‘ coolant

Operation: Drill & counterbore

Criterion: Reduce cycle time

Fixturing: Bespoke

Tool: SD290A-7.21-835758, custom drill & chamfer

Cutting vc f L4 D

data Metric 29 m/min 0.025 mm/rev 7.5 mm 7.21 mm

Inch 95 sf/min 0.001” ipr 0.296” 0.284”

results reduced cycle time by 66% by allowing increased

cutting data and combining two operations.

medICal

CetSolutIonChallengeDevelop a new process for acustomer in conjunction with a new machine tool purchase incorporating new toolingtechnologies and automatic load/unload concept. key ConSIderatIonS• Deliver a dependable com-

plete process with predictable tool life

• Meet with or improve on original time estimation from machine tool builder

• Manage turnkey element including workholding and automation

• Train existing personnel on new process

reSultS• Validated process, depend-

able tool life• Resultant cycle time in line

with MTB estimate (10% improvement using Jetstream Tooling®)

• 90% up time on all aspects of the process

oIl & gaS

CetSolutIon

fluId end – perfomax® modular drIll

fluId end – hIgh feed maChInIng

Material: 4340 HRC 38 - 42 (SMG 5)

Coolant: Internal coolant (120 PSI)

Operation: Large hole drilling (111 mm, 4.37 Inch)

Criterion: Productivity and reduced cost per part

Tool: SD601-3500-50RG

Insert: SCGX09T308-P1 & SCGX120408-P1, T3000D

Cutting vc n

data Metric 98 m/min 354 rpm

Inch 324 sf/min 354 rpm

Cutting vf f

data Metric 51 mm/min 0.15 mm/rev

Inch 2.01”/min 0.006”/rev

results no existing pre-hole or centering consistent

and reliable tool life10 holes (one fluid end) comple-

ted without reaching tool life limits.

Material: 4340 (SMG 4)

Coolant: Yes

Operation: Interpolation of bores

Criterion: Cycle time reduction, Economical solution

Tool: 2” diff pitch high feed, R220.21-02.00-R160.5A

Insert: 218.19-160T-04 MD09, MP3000

Cutting vc fz

data Metric 121.9 m/min 1.27 mm/tooth

Inch 400 sf/min 0.050” ipt

Cutting ap ae

data Metric 0.635 mm 93.47 mm

Inch 0.025” 3.68”

results ran with a 15‘‘ gauge length, interpolating out bores

on 4340 luid ends.

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ChallengeCreate a stable manufacturing process to overcome machining restraints. key ConSIderatIonS• Apply appropriate machining

solution for existing machinery• Increase operator awareness• Manage component costs• Develop improvements with

workholding supplier

reSultS• Reduced cycle time by 25%

with Seco high feed solution for face milling

• Achieved cost savings through Seco Point inventory manage-ment

• Trained operators through Seco product centre

• Created new workholding solution

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your ChallengeSSafe In our handSlet SeCo Cet help to grow your profItabIlIty To find out more about how you can utilise the services offered by Seco CET, please contact your local Seco Sales Unit or go to www.secotools.com

SeCo toolS abSe-737 82 fagerSta, Swedentel. +46 223 400 00www.SeCotoolS.Com

02895540, ST20136410 GB, © SECO TOOLS AB,2013. All rights reserved. Technical specificationsare subject to change without notice.Printed by Elanders 2013.