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ULTRA HARD TOOLS

Tools with an ultra hard cutting edge based on various kinds of diamond and cubic boron nitride (CBN) enable the application of completely new cutting strategies which manifest themselves with:

  • productivity increase of machining,
  • result quality improvement of the workpiece surface,
  • major decreasing the final number of machining operations,
  • enormous durability.

Ultra hard cutting materials Rotana can be divided into two main groups regarding their chemical composition, resulting hardness and chemical affinity of machined materials.

„These progressive cutting materials are difficult to machine using common conventional technologies. Thanks to implementation of the most advanced technologies, the company Rotana a.s. has facilities which enables effective processing of these advanced materials.“

MATERIALS BASED ON DIAMOND

can be divided into monocrystalline and polycrystalline materials. Polycrystalline materials are further divided into PKD and CVD-D on the bases of structural links.

Polycrystalline diamonds PKD are created by fusion sintering of the diamond powder with a suitable binder, most often based on cobalt CO, on a supporting carrier of solid carbide. Therefore, it is a heterogeneous mixture. Thickness of the diamond layer ranges from 0.5 to 1.5 millimetre.

„The application of these advanced materials are suitable for high speed cutting (HSC).“

CVD-D (Chemical Vapour Deposition of Diamond) diamonds are created by vapour condensation on a suitable base. The mixture of hydrogen with methane is bombarded with charged particles or directly with plasma. The subsequent chemical reaction will cause “rain“ of carbons falling on the base where they become hard in the form of diamond. Thickness of the diamond layer ranges from 0.8 to 1.2 millimetre. It is a hi-tech cutting material which does not contain any external binder. This parameter influences microgeometry of the cutting edge which will show enormous durability of the cutting tool, but also the resulting quality of machined areas.

These advanced materials are suitable to use for machining nonferrous metals and their alloys (Al, Cr, Zn, Mg, Ag) and non-metallic materials (plastics, glass laminates, graphite, composite materials).

The application of diamond tools is limited depending on the chemical affinity between the tool and the material of workpiece (diffusion of carbon from the crystalographical grid of diamond to the material of workpiece). The alloys containing iron, cobalt, manganese, nickel, chrome and platinum are not suitable for applying tools with the diamond cutting edge. Further, carbide-forming elements, (wolfram, tantalum, titan, zirconium, etc.) react with diamond at high temperatures to form relevant carbides.

MATERIALS ON THE BASE OF CUBIC BORON NITRIDE (CBN)

Polycrystalline cubic boron nitride PCBN is a highly effective cutting material which is fusion-sintering of cubic boron nitride with a suitable binder, mostly base on aluminium Al.

Cubic boron nitride CBN is a fully synthetic material which is, after diamond, the hardest known substance. Due to the chemical inactivity to iron metals, it is determined for machining this group of materials.

  • Hardened steel (45HRC-65HRC)
  • Heat resistant materials
  • Grey and hardened cast irons
  • Materials difficult to machine based on cobalt and nickel
  • Highly abrasive materials..

 

Further information about new technologies here.

Special tools

Special tools

We design the tools to satisfy your specific requirements. According to the specification of workpiece, we are able to design and produce a complete, adequate tool where standard tools cannot be used (or can be used with limitations only).

A special tool can be used also in the applications where a complex combination of standard tools reduces productivity of machining. By a using the special tool, it is possible to reach an improved optimization of production processes and thus increased productivity of machining.

 

„A close cooperation with our customers when developing technically demanding solutions for machining of challenging parts is the basis of the whole application success.“

Milling tools

Tools for milling operations

Monolithic shank milling tools from solid carbide intended for the area of HPC (High Performance Cutting), HFC (High Feed Cutting) and HSC (High Speed Cutting).

Various tool modification:

  • shape tools in accordance with DXF-line (according to your workpiece, according to our design),
  • cylindrical, radius, radius-conical, spherical, conical, ...,
  • one tooth as well as more tooth,
  • drilling as well as grooving,
  • extended,
  • internal, external cooling.

​Our tools cut materials such as stainless materials (Inconel, hastelloy, Nimonic), super-alloy, titan, aluminium, copper, graphite or composite materials.

Tools for machining holes

Tools for cutting of opennings

Monolithic tools for machining holes from solid carbide with the suitably selected coatings, various geometry and design, allow to machine holes with a high productivity when keeping the quality of machined surfaces in various applications and machined materials.

Various modifications of tool:

  • step and special drills, centre drill, reamers, recess tools (according to your workpiece, according to our design),
  • with various geometry, according to the type of use,
  • one tooth as well as more tooth,
  • including internal cooling with a straight as well as spiral flute,
  • extended.

 

Micro-tools

Micro-tools

Miniature structures can be produced by more technologies. Among them, machining is a very suitable method not only with regard to the expenses, a possible variability, but also with regard to environmental aspects.

„Fine details are critical for your micro-machining!“

Micro-tools are designed according to your specific requirements, especially in accordance with a final shape of workpiece, worked material, etc. Due to a close collaboration during designing, implementation, and subsequent optimization, it is possible to produce a special tool satisfying your production processes.

The main portfolio of produced tools is: milling, machining holes, turning.

Various modifications of tool:

  • diameters 0.1–3mm,
  • accuracy ± 1μm,
  • special micro-geometry,
  • various geometry of head,
  • shape according to DXF-line.
     
Micro-tools

Inserts

Exchangeable cutting tips

 

Continuous development of cutting process results in optimization of tools productivity. Special inserts Rotana have to comply with the continuously increasing requirements for geometry of cutting edges. It is the only way how to satisfy the methods of fast material removal (FMR).

 

„Save time by using the special inserts from Rotana!“

 

The company portfolio Rotana a.s. is not only the treatment of inserts but also the production of monolithic turning tools from solid carbide. The advantage of these tools is a significant variability of resulting shapes that is based on the final shape of workpiece.

Treatment of standard inserts to a non-standard geometry, a required shape can be obtained from the semi-products of inserts of renowned producers., e.g. of NCT, TOP NOTCH, etc.

 

Treatment of inserts consists of:

  • adjustment of shape of recessing, milling tips
  • resharpening of single tips
  • resharpening of special front shapes
  • resharpening of exchangeable tool heads (Seco, Kennametal, Iscar, etc.)
Rotana a.s.
Průmyslová 2085
59401 Velké Meziříčí

tel.: +420 566 521 948
fax: +420 566 522 057

mobil: +420 733 347 270
email: rotana@rotana.cz

 

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