Knowledge

DirectCooling system for turning tool holders

Accurate rather than spurted on: a new dimension of cooling tool cutting edges

Anyone who wants to use their resources sustainably is always looking for alternatives to flood lubrication. Now they need look no further than the new MaxiLock-S-DC turning tool holder, whose two internal holes ensure that the coolant is applied precisely to the cutting edge. One hole targets the rake face from above and the other the flank from below – applying to the cutting edges precisely. In this case, not all good things come from above. By contrast, flank cooling boosts the service life by 60% compared with cooling exclusively on the rake face. 

How does DirectCooling (DC) work?

Tool holders with DirectCooling (DC) are equipped with two inner holes that guide the coolant to where it has the greatest impact: directly at the cutting edge. One hole targets the rake face from above and the other the flank from below. Why is this so important? Targeted cooling improves both the service life and general process security. 

The VDI square adapters – DC (1) can be combined with the MaxiLock – S-DC rotating holder (2) and the MonoClamp – GX-DC grooving holder (3)

The lengths of all DirectCooling holders are ideally matched to one another. As a result...

  • Interference contours are eliminated
  • A compact complete package is created
  • Optimum stability is reached
  • Unlimited flexibility is achieved
Advantages of the universal VDI adapter – DC
  • The VDI holder with DirectCooling is incredibly versatile owing to its 4-in-1 functionality 
  • Thanks to its double tooth profile, only one holder is needed (two variants would typically be necessary for normal and overhead applications)
  • Optional extra: the clamping rails can be attached at the top or bottom to eliminate the need for an extra holder on the left and right
  • The danger of trapped chips is reduced
  • It ensures reduced overall wear
  • DirectCooling can be used for any application; the only prerequisite is that the coolant must be transferred via the turret of the turning centre or turning-milling centre
  1. Top clamping rail
  2. Bottom clamping rail
  3. Top tooth profile (normal application)
  4. Bottom tooth profile (overhead application)
Advantages of the MaxiLock-S-DC turning tool holder
  • Sustainable alternative to flood lubrication
  • Accurate not liberal, precisely applied not spurted on: the DirectCooling (DC) system applies coolant exactly where it is needed.
  • Can be used for any application from a coolant pressure of 10 bar
  • Compatible with turning centres or turning-milling centres on which coolant is transferred via the turret
  • The revamped insert seat of the turning indexable insert reduces wear on the cutting edges and creates better surfaces on the workpiece
  • Interference contours are eliminated: the lengths of the holders from the DirectCooling series have all been ideally matched to one another and also offer optimal stability and unlimited flexibility.
  • The nozzles of the MaxiLock-S DC turning tool holder can be replaced – for long, accurate cooling.
  1. Triple cooling (rake face and flank)
  2. G1/8" lateral coolant connection
  3. Coolant transfer from below via adapter possible
  4. G1/8" rear coolant connection
Advantages of the MonoClamp – GX-DC grooving holder
  • DirectCooling can be used for any application; the only prerequisite is that the coolant must be transferred via the turret of the turning centre or turning-milling centre
  • The MonoClamp GX-DC tool holders are ideal for deep grooves, as a high flow volume reliably flushes out any chips
  • The danger of trapped chips is reduced
  • DirectCooling ensures reduced overall wear
  • The revamped insert seat clamps the grooving insert in the insert holder with even greater stability
  • Better handling – changing inserts could not be easier, as the insert clamping screw can be turned from both above and below
  1. G1/8" rear coolant connection
  2. Coolant transfer from below via adapter possible
  3. G1/8" lateral coolant connection
  4. Dual cooling (rake face and flank)
So, in terms of transfer, instead of emptying a bucketful into the machining zone, we target the cutting edges precisely.
CERATIZIT Product Manager, Paul Höckberg

Test report: Longitudinal turning of 1.4301

Indexable insert: CCMT 120408EN-M55 CTPM125
Material: 1.4301 – X5CrNi18-10
Cutting data: vc 200 m/min | f 0.25 mm/U | ap 2 mm

Result: With the DirectCooling cooling system, the tool life can be increased by 63% compared with a conventional cooling situation.

What's interesting here is that the lower coolant hole on the flank of the indexable insert has a considerable influence on the tool life. While cooling exclusively through the upper two nozzles gives rise to an improvement of just 22%, flank cooling achieves an increase of 54% compared with standard cooling!