With ongoing volatility in raw material markets and tightening global supply chains, tooling manufacturers are under increasing pressure to balance performance with cost control.
FETTE Werkzeugtechnik, part of the
LMT Tools group and a specialist in gear cutting, has introduced its SpeedCore hob cutter as a response to these challenges, offering what it describes as a high-performance yet cost-effective alternative to carbide tooling.
Carbide tools have long been favoured for their cutting performance, but their dependence on critical raw materials such as tungsten and cobalt has made pricing and availability increasingly unpredictable. Against this backdrop, manufacturers are seeking alternatives that can deliver comparable productivity with greater supply security. FETTE Werkzeugtechnik says its SpeedCore solution meets that need.
The cutter is manufactured from a specially developed high-performance high-speed steel, designed to bridge the gap between conventional powder metallurgical high-speed steel (PM-HSS) and carbide. According to the company, the material enables cutting speeds up to 50% higher than traditional PM-HSS tools while maintaining process reliability. This is achieved through controlled intermetallic phases that enhance thermal stability and heat resistance, allowing the tool to withstand higher thermal loads in operation.
In addition to material development, process optimisation is highlighted as a key factor in unlocking the tool’s potential.
FETTE Werkzeugtechnik approaches machining as an integrated system, considering the interaction between tool, workpiece, machine and strategy. Process parameters are tailored to suit specific materials, component geometries and operating conditions.
Raphael Lienau, managing director of FETTE Werkzeugtechnik explained: “Unlike generic parameter recommendations, LMT Tools designs solutions that are material and application specific. The goal is to utilise the most economical process window in each case without compromising process reliability.”
Performance gains have been demonstrated in practical applications. In one case involving the production of a module nine gear for a planetary gearbox used in mining machinery, a SpeedCore cutter with a Nanosphere 2.0 coating was compared with a TiN-coated EMo5Co5 high-speed steel tool. Machining time was reduced from 50.9 minutes to 26.2 minutes, approximately a 50% improvement, placing the tool in a performance bracket traditionally associated with carbide insert systems.
The single-piece design of the SpeedCore hob cutter also contributes to improved accuracy, reduced tooling costs and a higher effective tooth count. FETTE Werkzeugtechnik says that such benefits, combined with enhanced supply stability, make the solution particularly attractive for manufacturers seeking both productivity and predictability.
Mr Lienau concluded: “The key strength lies not only in the material itself, but in the ability to specifically adapt it to application specific processes. It is only through this integration that real added value is created for the user.”