��Smart solutions in metal cutting HSS " FORUM HSS FORUM CONFERENCE February 2nd and 3rd 2005, Aachen New Technologies in the Cutting Tool Industry Eugen VALERIUS, President of the HSS FORUM Adeline RIOU, Marketing Manager, ERASTEEL p 1 HSS " FORUM Read in the press �HSS has the ability to withstand stresses far beyond the tolerances of carbide� p 2 � h n s o � i o H S n s S i m r y t e i r o m d o a e l i v n l m s t a l y i t t i t e l h a r e w l n i i a a p u l S r c m e S i i f a n H e t p r � a p m r l a e m i n d e a l c y r a r e t o d e i m o t � n H s s S e S t b d o d c e a o d e y n l � t p n i u s n e o u h c e h w s � g g t w i l o n o H a i e l � c r l i o o e d m o e r o � t a n o s c d e e e p s HSS " FORUM Contents Facts and figures by area Facts and figures by metal cutting technologies Facts and figures on new technologies p 3 HSS " FORUM Facts and figures by area p 4 HSS " FORUM Tool consumption by area (in %) A world tool consumption of $11 billion in 2003 % 35 30% Western Europe 30 25 25% NAFTA (North America) 20 17% Other Asia 15 12% Japan 10 10% CIS, Eastern Europe 6% South America 5 and other areas 0 1985 1995 2005 Note: saws not included Source: HSS FORUM p 5 HSS " FORUM Mechanical industry by area (in %) A market of � 1115 billion in 2002 in Europe, USA and Japan Million � 600 000 500 000 43% USA 400 000 300 000 21% Japan 200 000 18% Germany 100 000 7% France 6% Italy 4% UK 0 1% Spain 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Source: Eurostat, OECD etc. p 6 HSS " FORUM Machine tool consumption by area (in %) A world consumption* of $25 billion in 2003 (metal forming not included) Significant growth in other Asia and and strong decline in North America Mio. US-$ 13 000 12 000 11 000 10 000 34% Other Asia 9 000 8 000 32% Western Europe 7 000 6 000 15% NAFTA (North 5 000 America) 4 000 15% Japan 3 000 2 000 1 000 4% CIS, Eastern Europe 0 and other areas 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 * Machine tools for metal removal only (metal forming machines are not included) Source: American Machinist and subsequent publisher p 7 HSS " FORUM Automotive production by area (in %) A total production of 62 million vehicles in 2003 Development of Asian vehicles production 000 units 20 000 18 000 28% Western Europe 16 000 26% NAFTA (North 14 000 America) 12 000 18% Other Asia 10 000 16% Japan 8 000 6 000 7% South America 4 000 and other areas 2 000 5% CIS, Eastern Europe 0 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Source: Automotive News p 8 HSS " FORUM Facts and figures by metal cutting technologies p 9 HSS " FORUM World metal cutting tool market in 2003 A world tool consumption of $11 billion in 2003 Gear cutting 3% Broaching 3% Reaming, Turning counterboring 25% 7% Tapping 14% Drilling Milling 20% 28% * Sawing (not included above) is estimated to represent a similar volume as tapping Source: HSS FORUM p 10 Tool materials in 2003 HSS " FORUM in different metal cutting technologies Turning Milling 2% brazed 9% solid carbide carbide 33% HSS 58% inserts 98% inserts Drilling Tapping 5% solid 22% solid carbide carbide 51% HSS 27% 95% HSS inserts Source: HSS FORUM p 11 Tool materials in 2003 HSS " FORUM in different metal cutting technologies Reaming Gear 19% solid Counter- cutting carbide 26% HSS boring 50% solid and brazed carbide 24% inserts 81% HSS Sawing 14% Broaching 5% brazed carbide carbide tips 86% HSS 95% HSS Source: HSS FORUM p 12 HSS " FORUM Evolution by tool material Million US Dollars 12 000 11 000 Total 10 000 9 000 8 000 7 000 6 000 48% inserts & holders 5 000 4 000 36% HSS 3 000 2 000 16% solid & brazed 1 000 carbide 0 Note: saws not included Source: HSS FORUM p 13 8 9 2 3 95 96 999 000 003 1985 1986 1987 198 198 1990 1991 199 199 1994 19 19 1997 1998 1 2 2001 2002 2 HSS " FORUM Facts and figures on new technologies New technologies ? p 14 HSS " FORUM Tool materials  the traditional view 95% of the metal Wear MCD + PCD cutting market resistance, CBN Hot hardness, Speed Al203 Al203 + TiC Si3N4 Cermets Cemented carbides HSS Increasing Toughness, Transverse Rupture Strength, Feed p 15 Increasing HSS " FORUM Tool materials  today s view Material developments Wear MCD + PCD resistance, CBN Hot hardness, Speed Al203 Al203 + TiC Si3N4 Cermets micro grain PM-HSS, higher V Cemented carbides higher purity carbides PM-HSS PM-HSS, lower Co higher V, higher purity higher Co PM-HSS higher V, lower Co HSS Increasing Toughness, Transverse Rupture Strength, Feed p 16 Increasing HSS-PM technology HSS " FORUM in HSS metal cutting tools Consumption Gear cutting tools 70% HSS-PM Maturity Broaches 50% HSS-PM Conventional HSS Endmills 20% HSS-PM Taps Growth 10% HSS-PM Drills 1% HSS-PM HSS-PM Introduction Product life cycle Source: HSS FORUM p 17 PVD coatings HSS " FORUM in HSS metal cutting tools Consumption Gear cutting tools TiAlN 90% coated TiN Maturity Taps 50% coated TiCN Drills, Endmills MoS2 45% coated Broaches 40% Growth WC/C Introduction Product life cycle Source: HSS FORUM p 18 Oil-hole technology HSS " FORUM in HSS metal cutting tools Consumption Maturity Oil holes in drills Taps 10% Drills 5% Growth Oil holes in taps Introduction Product life cycle Source: HSS FORUM p 19 HSS " FORUM Conclusion There are today many efforts from tool manufacturers to � bridge the gap � between carbides and HSS in the direction of the ideal cutting material, at different levels: " HSS-PM " Coatings " New geometries Interesting evolutions are expected in the field of metal cutting for improved: " Tool performance " Tool reliability and safety " Tool life " And machining costs. p 20 HSS " FORUM Last word: The HSS Smart Guide The latest publication of the HSS FORUM Comments from readers: � Ein hilfreiches tool f�r mich� Mr Pilz, Austria � This is the best HSS guide I ever read� Mr Chen, Singapore � Your HSS Smart Guide was really useful for us� Mr Tham, Malaysia � We congratulate on the excellent publication, which is very useful to practicing engineers� Mr Sriram, India � The information contained in that book is very easy to understand and it really helps me� Mr Puspasari, Indonesia � There are very useful information for us in this guide� Mr Monka, Slovak Republic � Wir finden diese Lekt�re au�erordentlich interessant und gut gelungen� Mr Lemke, Germany Soon available in German, French, Italian and Spanish p 21