Tangential-Rollsystem TSW18
The switch to a tangential knurling system from Wagner Tooling Systems enables consistently high knurling quality without over-knurling, reduces machining time to just 1.8 seconds, and significantly lowers tooling costs—ideal for highly productive large-scale production processes.
Task
Application:
- Knurling a motor shaft
- RAA 1.0 / Ø 18.25 mm
- Knurling length 14 mm
Material:
- 1.7225 (42CrMo4)
(tensile strength 900–1200 N/mm2)
Current process / customer request:
- High reject rate due to overlapping of the knurl is to be reduced
Solution
- Process changeover to TSW18 tangential system with knurl and support roll
Customer Benefit
Quality:
- No overlap on the knurl
- Consistent and repeatable accuracy
Cost reduction:
- Reduced tooling costs (purchase of single rolls possible)
Process:
- Stable tool body is optimally suited for large series
Time saving:
- Processing time approx. 1.8 seconds
Axial-Rollsystem RS22-2
Improved manufacturing of trapezoidal spindles: perfect surfaces, significantly longer service life, and extremely fast machining. The result is a highly productive, reliable, and self-sufficient manufacturing process for series production..
Task
Application:
- Trapezoidal spindle / seat adjustment, Tr12 × 3, length: 185 mm
Material:
- 1.0401 (tensile strength approx. 740-880 N/mm2)
Current process:
- Optimization of surface quality
- Optimization of the tool life of the thread rolls
Solution
- Changeover to axial rolling system RS22-2 with closing device and rolls specially designed for the application (roll lead A5)
- Rolling speed 30 m/min
- Speed 930 rpm
- Processing time 4 seconds
Customer Benefit
Time saving:
- Very short machining time
Quality:
- The rolling system in combination with the thread rolls (roll lead A5) optimally absorb the forces. This results in better surface quality and service life of the rolls.
Process:
- The rolling system with integrated closing device forms a self-sufficient unit, as the system can be closed during non-productive time.
Mehrschneiden-Drehsystem MSD20
By using two multi-cutter turning systems on a newly constructed rotary transfer machine, it was possible to combine the shortest cycle times with the highest surface quality. Despite the long clamping length, the components are centered reliably and manufactured with consistently repeatable dimensional accuracy—a solution for maximum productivity and the highest quality.
Solution
Application:
- Heating module
Material:
- 1.0711 Automatenstahl
(tensile strength 440 N/mm2)
Lot size:
- 1,000,000 parts per year
New process / customer request:
- Rebuild of a rotary transfer machine
- Use of two multi cutter turning systems
- Pre-machining of the diameter must not determine the cycle time
- Surface quality of RZ 10 must be achieved during finish turning
Solution
- Use of the multi cutter turning system MSD20 with counterpressure unit: Speed 3500/min. and f = 0.30 mm for roughing
- Use of the MSD20-R multi cutter turning system for finish cutting. Speed 3500/min and f = 0.20 mm
Customer Benefit
Process:
- Cutting forces cancel each other out due to opposing cutting edges. Workpieces with a large clamping length can be machined in this way.
- Workpiece is centered by 4 cutting edges
- Easy handling due to central diameter adjustment
Quality:
- Consistent and repeatable dimensional accuracy