Bohemia Rings specializes in the complete production of large bearing rings for a wide range of applications. Our task was to ensure efficient tool cooling for a new vertical lathe supplied by Omos. The machine is equipped with a pump delivering up to 70 bar of pressure and a flow rate of 120 l/min, providing ideal conditions for the use of high-pressure cooling principles.
Our solution
The project was carried out in cooperation with Dormer Pramet. For machining 42CrMoS4+QT (15142.6), the SSBCR 6060 V38A tool was selected. The customer required a cutting depth of up to 22 mm and a feed of 1.5 mm, which made efficient cooling along the entire cutting edge essential.
We developed two innovative components:
ECHO insert support pad with integrated channels for flank-face coolant supply, replacing the standard pad.
ECHO top clamp with coolant delivery from the rake face, ensuring precise coolant flow to the cutting zone.
Implementing our solution required just minimal changes to the original tool body – mainly drilling coolant supply holes for the new cooling elements.
Challenges and finding the optimal solution
One of the main challenges was achieving effective cooling on the rake face of the tool. The original design, which delivered coolant very close to the cutting zone, provided high efficiency but was prone to wear of the rake element in situations where chip formation was not ideal, such as during tool entry into the cut.
Therefore, we developed a second version of the top clamp, which is significantly more durable and provides greater reliability during long-term operation.
Results and benefits
✅ Tool wear reduced by more than 50% thanks to intensive cooling.
✅ Higher productivity enabled by increasing cutting speed from 80 to 120 m/min.
✅ Long-term reliability, minimizing downtime caused by tool wear.
We handle design, modifications, and component manufacturing in-house – ensuring fast implementation and full control over the process.
Testing carried out directly at the customer’s site demonstrated a significant benefit of precisely targeted cooling when machining this alloy steel, helping the customer optimize their production process and increase productivity.
Improved chip management
Tool wear comparison
| Original tool | ECHO Tools cooling |
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