The famous quote “Genius is 1% inspiration and 99% perspiration” is often credited to inventor Thomas Edison. Actually, many claim we should be thanking author Kate Sanborn for the wise words. Regardless of their author, the sentiment resonates with many inventors — innovation is rarely a lightbulb moment. Per-Anders Stjernstedt, Senior Engineer at metal cutting expert Sandvik Coromant, understands all-too-well that innovation is a labour of love. In this article, he explains the latest innovation in turning from Sandvik Coromant.

Like any inventor, Sandvik Coromant began with a challenge to solve. How can tooling overcome delays, reduce downtime and support faster production? Software company Senseye’s True Cost Of Downtime 2022 report reveals unplanned downtime costs manufacturers at least 50% more today than it did in the period 2019 to 2020. The same report states that unplanned downtime will cost Fortune Global 500 industrial companies almost $1.5 trillion USD in 2023, equating to 11% of their revenues.

To reduce time wasted changing tools, improve process stability and improve tool wear, manufacturers needed the ability to machine several features with a single tool. And here lies the raison d’être for Y-axis turning. Let’s examine how it works.

Turning angles
First, it’s helpful to think about entering angles. Choosing the correct angle between the cutting edge and the feed direction is vital for a successful turning operation, as it influences chip formation, direction of cutting forces and cutting edge length in cut. An angle that’s higher than what’s required results in a weak cutting edge. One that’s too small might cause the tool to rub at high feed rates, ultimately leading to breakages.

In 2017, Sandvik Coromant developed PrimeTurning, a turning concept that enables ‘all-directional turning’ for greater machining flexibility. Based on the tool entering the component at the chuck and removing material as it travels towards the end of the component, PrimeTurning allows for the application of a small entering angle, higher lead angle, and the possibility of machining with higher cutting parameters.

Alone, PrimeTurning is an innovative feat for turning. But as well as the productivity gains made through chip control, the team also wanted to help manufacturers machine more complex and innovative shapes. PrimeTurning acted as one of several building blocks that led to the development of Y-axis turning.

Entering at the Y
So how does Y-axis turning work? As the name implies, the new method makes use of the Y-axis, and all three axes are used simultaneously when machining. The tool rotates around its own centre, the insert is placed for machining in the Y-Z plane and the milling spindle axis interpolates during turning. This way, intricate shapes can be machined with a single tool.

Y-axis turning offers numerous benefits. The possibility to machine several features with only one tool reduces cycle time. The fact that no tool changes are required also minimises the risk of ‘blend points’, or irregularities between adjacent machined surfaces. Main cutting forces are directed into the machine spindle, improving stability and reducing the risk for vibrations. To improve surface finish, wiper inserts are designed with a wiper edge that is situated where the straight edge meets the corner radius.

The method also helps keep chip thickness at a constant, whether turning with a constant cut depth or turning contours in the workpiece. Because the width of chips doesn’t change, risk of chip jamming is significantly decreased. Not only does this allow for more reliable machining operations, but knowing turning can take place without any mishaps could allow manufacturers to step away from their machines and have them run without supervision.

Meet Per-Anders
Per-Anders is a Senior Engineer at Sandvik Coromant, and is based in Gävle, Sweden. Working for the company for over a decade, Per-Anders has been involved in the development of several innovations. One of his proudest to date is Y-axis turning.

“In past five years, I’ve developed five globally-recognised patents and filed twelve innovation disclosures last year. But Y-axis has been a real career highlight for me,” he said. I like to think I’ve always been an inventor. In my younger years, I was always causing havoc in my father’s garage and experimented with a whole host of passion projects. There were surfboards, motor cycle frames and fixtures and, when I wanted to borrow my parents’ camera equipment for a diving trip, I built the underwater housings so I could film my expeditions.

“Despite this creator’s spirit, none of my engineering successes happened overnight. In the case of Y-axis turning, the team and I went through a six-year cycle of research and development before we got our big breakthrough.”

Crafting the future
Developing Y-axis turning was a labour of love. “When the team began, we had an idea that the market had never seen before. It took time to prove that our ambitions could be realised but, after a lot of internal testing, we’ve already seen a 51% reduction in cycle times using Y-axis turning over competing methods,” Stjernstedt revealed.

To complement Y-axis turning, Sandvik Coromant has also developed a new CoroTurn® Prime variant suitable for shafts, flanges and components with undercuts and the CoroPlex® YT twin-tool, which is best used at an entering angle of between 60 to 90⁰ for more productive machining.

Reflecting on his career, Stjernstedt said: “My advice for anyone with a big idea — just begin. If you’ve spotted a challenge without a solution, you’re already halfway there. I’m lucky Sandvik Coromant gives me the freedom to experiment and learn as I work. Being an engineer doesn’t only require the technical knowledge to develop new products. You have to be a creative thinker, a problem solver and unafraid to challenge the status quo.”

No matter who said “Genius is 1% inspiration and 99% perspiration”, they weren’t wrong. Having the technical skills and ability to develop new solutions is vital, but a lot of invention is the result of hard work. Per-Anders and his team wouldn’t have succeeded without dedication, patience and the determination to re-define turning.

To celebrate “World Water Day” on March 22, 2023, metal cutting specialist Sandvik Coromant India inaugurated its wastewater treatment plant at the Talawade Garden in Pune, Maharashtra, India. The inauguration, which took place on March 23, 2023, is the fourth wastewater sustainability project that Sandvik Coromant has facilitated in collaboration with Pimpri-Chinchwad Municipal Corporation (PCMC).

Untreated sewage waste is a major cause of surface water and groundwater pollution in India. In particular, Pimpri-Chinchwad is one of the most developed and industrial cities in Maharashtra, and as a result, produces a large volume of wastewater that runs through its drainage system.

To combat this, Sandvik Coromant has been working with Pimpri-Chinchwad Municipal Corporation to install wastewater treatment plants across the region that treat flowing wastewater, promoting the recycling and reusing of water. The latest wastewater plant at Talawade Garden, which was installed in January 2023, recycles 5,000 litres of water per day. This is the fourth plant that Sandvik Coromant have collaborated on, with the other three located at Premlok garden, Babuji Golande Garden and Oxygen Garden.

At the ceremony, officials from PCMC attended, including Mr. Jitendra Wagh, Additional Commissioner, and Mr. Sanjay Kulkarni, Joint City Engineer along with other PCMC officials and members from Sandvik Coromant including Mr. Kiran Acharya, Managing Director and Chief Financial Officer, Mr. Vignesh Iyer, Deputy Manager Finance & CSR, Roshni Acharya, CSR Specialist and other global delegates of Sandvik Coromant, and spoke to the public about the initiative to create awareness about wastewater and the possible alternatives.

“Water is a scarce resource and Sandvik Coromant takes our responsibility as a local manufacturer very seriously, and this initiative of the wastewater treatment across the 4 gardens would help to treat 9.1 million litres of waste water which can be used for gardening and the utilization of fresh water can be optimized. Taking action towards sustainable development goals (SDGs) is a priority for Sandvik Coromant India, and these wastewater plants are just one of multiple sustainability projects that we’ve initiated in India. The need to treat wastewater efficiently is becoming more prominent and we’re setting an example of how this can be done. We have pioneered and launched the initiative of recycling wastewater to maintain the gardens with wastewater plants”, said Mr. Kiran Acharya.

Mr. Jitendra Wagh, Additional Commissioner PCMC added that “The collaboration between PCMC and Sandvik Coromant, shows the efforts and the results that this wastewater initiative at the Talawade garden will also help the local community. The wastewater is treated at the source, and the fresh water is now being used in the garden and can be put to a fruitful use for the community.”

As a result of its efforts to save water, Sandvik Coromant India also received the ‘Best urban wastewater management award’ at the Global CSR Excellence & Leadership Awards in 2022.

“Honouring World Water Day with the ceremony was a prominent way to demonstrate why wastewater treatment plants are so crucial to the messaging of not just what clean, safe water means not just in India, but globally,” continued Mr Kiran Acharya. “This initiative reflects the continuity and the sustainability potential that Sandvik Coromant looks for in a project. It also supports our constant endeavour to give back to society. While India is already performing highly in its actions against climate protection, Sandvik Coromant is paving the way for major sustainability transformation.”

Cutting tool specialist Sandvik Coromant expands its offer of CoroMill® Plura HD solid-end mills for heavy-duty roughing in steel and stainless steel with two new grades. This new generation of grades features the unique Zertivo 2.0 coating, which combines world-class productivity with exceptional metal removal rate and the highest possible process security.
CoroMill® Plura HD is Sandvik Coromant’s first choice optimized solution for heavy-duty applications up to 2×D in steel and stainless steel (ISO P and ISO M), offering safe and efficient solid end milling. Thanks to the new Zertivo 2.0 coated grades tool life, process security and productivity are improved even further.

“With Zertivo 2.0 we apply our comprehensive knowledge in coating technologies to our solid round tools”, says Antti Wikström, Global Product Manager, Solid end mills at Sandvik Coromant. “This gives us an opportunity to offer unique, custom-made coatings that will handle our customers’ machining challenges with superior performance and tooling efficiency.”

The new grades allow for 30% higher cutting speed recommendations in primary application areas ISO P and ISO M, as well as secondary materials ISO K and ISO S, due to their optimized flute shape, which provides effective chip evacuation. The grades designed for stainless steel machining come in two variants: one with internal coolant for improved temperature control and chip flow, and one without internal coolant.

The standard assortment offers diameters from 2–25 mm, a 2×D depth of cut, 4 to 5 teeth, and a ramping angle at 5° or 7°. Tailor Made® options are available within the Customized solutions range.

Supply chain resilience has been a thread weaved throughout the manufacturing industry in 2022. To combat ongoing uncertainties across the ASEAN region, more firms are turning towards India for resilience. In fact, we’re seeing an increasing dependance on the nation to help deliver in areas others still face challenges. There are several trends that demonstrate India’s fortitude during the year as Sunil Joshi, President of Sales for Sandvik Coromant India explains.

It’s been a turbulent year in many respects. Across the globe, energy costs have increased by between 25% and 90% and, in extreme instances, by as much as 300% over the last year. The ongoing logistics disruptions stemming from the COVID-19 pandemic continue to impact businesses, creating a ripple effect across global supply chains.

Furthermore, manufacturers are also faced with something of a sustainability paradox. One the one hand, there’s pressure to deliver products at higher speeds and at lower costs. On the other, they’re facing growing scrutiny from investors, partners and local governments to adopt more sustainable ways of working.

But it’s not all doom and gloom. Despite encountering challenges that could easily throw the industry’s resilience into question, many manufacturers will enter 2023 having weathered the storm. In particular, we’re seeing India shape up to become an ASEAN supply chain hub. With a concerted effort from the Indian government to deliver better transport infrastructure, the country now has the world’s second largest road and rail network. Furthermore, recent developments attest to the growing confidence in India as a manufacturing hub, such as Apple’s decision to manufacture its iPhone 14 in India.

With these challenges and potential in mind, let’s take a look at some of the trends impacting the metal cutting sector this year and beyond.

Getting lighter

Two years into the 2020s and the decade looks set to mark the beginning of a new shift in manufacturing — away from pure profit maximisation and towards a growth approach that incorporates the health of the planet at its core.

Today, manufacturers find themselves having to meet the sustainability needs of a variety of stakeholders. Public awareness of how industry can damage the environment has put emphasis on businesses to change their ways, as they can now be held accountable more easily. In fact, there’s a rising number of consumers who will pay a premium for eco versions of a product, YouGov reports. Having strong sustainability credentials can also make a business more attractive to suppliers and shareholders who have their own sustainability objectives to meet.

One way of satisfying the need for more sustainable products is to make them using lighter materials. If we take the aerospace industry as an example, pressure to lower air travel’s carbon footprint has placed an emphasis on making planes lighter, in order to save on fuel. Shedding weight will help bring down the high fuel consumption of planes. For instance, when United Airlines switched its in-flight magazine to lighter paper, it saved over 170,000 gallons of fuel a year. Every gram counts when making aircraft lighter, from large components such as the wing box, to intricate motors in reclining passenger seats.

Advances in materials have led to a variety of possibilities for aerospace companies. This has been seen through the increased use of composites and graphene, and also lightweight materials such as titanium. Other innovations in materials technology include the use of metal powers and additive manufacturing technologies to design lightweight and more sustainable metal parts.

Titanium is 30% stronger than steel, but nearly 50% lighter — making it a key component in addressing efficiency and sustainability challenges. However, machining materials such as titanium presents its own challenges. Titanium alloys can have double the hardness of steel alloys so, when paired with titanium’s low thermal conductivity, high thermal and mechanical loads are placed onto the tools tasked with cutting the metal. Manufacturers embracing the trend for lighter, yet more challenging, materials must therefore ensure they have access to the right cutting tools.

Elsewhere automotive manufacturing is also undergoing a lightweight revolution. Here, we’re seeing manufacturers turn to aluminium to save weight and make vehicles more sustainable. But aluminum alloys require complex machining with complex and cost-intensive processes and various tools. In addition to very time-consuming tool setups, inferior surface finishes, burr formation and inconsistent tool wear are not uncommon and manufacturers must lean on the right tools to efficiently machine the material.

A connected machine shop

Since, and as a result of, the pandemic, we’ve seen manufacturers across the globe adopt digital technologies at an unprecedented speed. Findings suggest the speed of digital transformation has hastened by several years — as many as seven according to McKinsey.

In India, strides towards digitalisation are being seen as Debjani Ghosh, President of the National Association of Software and Services Companies (NASSCOM) reveals in NASSCOM and Capgemini’s India Industry Adoption: A Case to Mature Manufacturing Digitalization by 2025 report. In the report, he says: “Industry 4.0 has reached a tipping point in Indian manufacturing […]. Moving forward, it will be fascinating to watch how ready the Indian manufacturing industry is to adopt and scale Industry 4.0, which is largely determined by the use cases selected, the capacity to scale proofs of concept, and the alignment of information technology (IT) and operational technology (OT) capabilities.” The report also found that Indian manufacturers spent between $5.5 and $6.5 billion dollars on Industry 4.0 technologies in 2021, with half that being spent on Cloud and IoT.

Achieving digitalisation at scale requires a multitude of disciplines to come together — namely machining knowledge, OT and IT as well as more specific technologies such as artificial intelligence (AI) and big data. Uniting all these areas into a single strategy gives manufacturers the resilience to adapt to change, streamline operations and futureproof themselves.

As companies seek to broaden their capabilities and digitalise, we’re seeing equipment providers and IT companies combine their niches to create a whole new level of value for their customers. This is a key part of Sandvik Coromant’s digital strategy, and will be for years to come. If we think of Sandvik Coromant’s niche, machining and metal cutting, our expertise lies in increasing the efficiency, reliability and repeatability of our customers’ machining operations. If we then look at a company like Microsoft and its Azure cloud computing platform, its niche is very different, but plays an important part in helping our own software solutions to deliver value.

When we combine niches from Sandvik Coromant and Microsoft, we create a specialism that brings a deeper understanding of digital services to the manufacturing space. The CoroPlus®  portfolio of solutions from Sandvik Coromant leverages our unique machining knowledge and integrates all elements of the production flow — people, machines, tools and data — to empower customers to make better business decisions. The solution combines the company’s deep experience in machining with digital solutions from partners such as Microsoft for an enriched portfolio that delivers efficient processes, planning and operations.

It’s a win-win model for both partners, and is how we foresee the manufacturing landscape continuing to flourish in the future. And we’re not stopping there. Moving into 2023, Sandvik Coromant’s mission will continue to revolve around shaping the future of manufacturing through digitalization. Other collaborations, such as Sandvik Coromant’s partnership with CGTech, the developers of simulation software Vericut, are also helping us to create digital synergies that will benefit the entire manufacturing value chain.

This year has certainly proved testing for manufacturers’ resilience. However, despite having storms to weather, several trends are helping to shape the present and future of the industry. We’re already seeing strides towards sustainability and growing investment in digital services, both of which will pave the way for a greener, leaner industry.

In June 2022, Sandvik Coromant hosted a four-day ISO standards development meeting at its Sandvik Coromant Center in Sandviken, Sweden. Focusing on how several digital standards, of which Sandvik Coromant helped to form, could enable a collaborative environment across digital machining platforms and unleash the full potential of digital manufacturing, the event welcomed an audience from disciplines across the metal cutting industry.

The event provided an opportunity for manufacturing representatives from across the globe to meet, exchange experiences and get first-hand insight into standards for digital manufacturing and examples of how to implement them. Participants included Sweden’s Scania, SECO Tools, Sandvik, SIS, Chalmers and KTH, TDM Systems, Zoller and Walter Tools from Germany, Boeing Company, Lockheed Martin, STEP Tools, Mastercam and NIST from the US, and ETRI and KRISO from Korea.

Attendees took part in live demonstrations from Sandvik Coromant, Zoller, Mastercam, TDM Systems, CRIBWISE and STEP Tools to showcase how embracing the standards can facilitate connected, collaborative manufacturing processes.

It’s a pertinent time to consider digital standards. According to MarketsAndMarkets, the global digital twin market size was valued at USD 3.1 billion in 2020 and is projected to reach USD 48.2 billion by 2026. That’s an expected annual growth of 58%. The way in which manufacturers design, implement and work with machinery is shifting, with as much activity being hosted in the digital as it is in the physical world. To advise on best practice for approaching new technologies, like digital twins, the ISO committee on industrial data has developed almost 800 standards, covering product lifecycle management for everything from the energy and aerospace industries, to everyday household products.

In particular, the committee has worked to develop several standards that support the use of process data in manufacturing. For several decades, Sandvik Coromant has offered its expertise towards the development, use case testing and evaluation of these standards. They include ISO 23247, ISO 10303 (STEP) and ISO 13399.

ISO 23247 supports the creation of digital twins for several elements involved in component manufacturing including the part being manufactured, engineering requirements (CAD), the manufacturing process (CAM) and the equipment needed, such as the machine tools, cutting tools and part handling devices. Using digital twins in manufacturing systems supports the faster and more efficient creation of better products and more efficient use of the equipment.

ISO 10303-238 (AP238), known as the STEP-NC standard, complements the ISO 6983 M and G code standard with an associative language that connects the CAD design data used to determine the machining requirements for an operation with the CAM process data that solves those requirements. Additionally, ISO 10303-242 (AP242) is an all-encompassing standard for managing 3D design models. Finally, ISO 13399 offers supports exchange of cutting tool data.

“We’ve worked with the ISO committee for many years, always with our customers in mind,” said Helen Blomqvist, President of Sandvik Coromant. “We believe the digital transformation of our industry is for everyone, and our work on these standards is essential for helping us share knowledge and best practices. It’s all about shaping the future of metal cutting together and ISO standards will be critical to support our customers now and in the future.”

Hosting the event was just one part of Sandvik Coromant’s digital agenda. “June’s event facilitated many fruitful discussions,” said Bengt Olsson, Product Information Specialist at Sandvik Coromant. “Our goal is to educate our entire, global network of partners and customers on the importance of these standards, and highlight exactly how they can influence the next generation of manufacturing. They’re more than just guidance, they’re the solution for Industry 4.0.”

According to PwC’s Industrial Manufacturing report, “The only constant in today’s industrial manufacturing environment is disruption.” Disruptions to supply chains and productivity, caused by the pandemic, have driven manufacturers to diversify to new markets to survive. This creates an increased need for error-free precision machining. Here, Sangram Dash, Product Application Manager for Indexable Milling at Sandvik Coromant, explains how the new CoroMill® MH20 high feed milling cutter can support error-free machining.

“To stay competitive,” continues PwC’s report, “organisations must be able to integrate new business models and technologies to accelerate and adapt.” For machine shops, adapting includes diversifying product offerings and being ready to satisfy customer demand in new markets.

They are also under pressure to diagnose and eliminate product defects through error-proofing. This is a growing challenge, because diversifying into new sectors means handling workpieces made from wider a range of materials like aluminium and heat resistant super alloys (HRSAs). The hardness values of these materials differ enormously from one end of the spectrum to the other. Processes and machining conditions will also vary widely from part-to-part. They include everything from roughing to finishing on out-of-round or near-net-shape cast or forged parts.

Certain types of machining also present unique challenges. For instance, when a tool with a long overhang is used to mill deep narrow pockets, the whole setup becomes unstable. This can lead to unpredictable machining and a higher risk of vibrations that, as we’ll explore, can cause tool failures and downtime.

Manufacturers instead need tooling solutions that provide secure and predictable machining, with increased metal removal rates, reduced cycle times and quick changes between production batches. Fortunately, a solution does exist. As PwC’s Industrial Manufacturing puts it, “with disruption comes the opportunity to innovate.”

Bad vibrations
Why are these innovations necessary? One factor that needs to be overcome is machining vibrations, which negatively affect performance in a variety of ways, including displacement of the tool and imperfections in workpieces. They can even cause tool breakage and unplanned downtime. Another problem with vibrations is the effect on chip formation and chip removal, which are the fundamental occurrences inseparably involved with machining that damage the effectiveness of cutting tools.

Another factor in milling tool underperformance is that most inserts have four edges. The reason for having four edges is that, when one edge becomes dulled or chipped, it’s an easy process to rotate or replace the tip. However, the insert’s corners, between the flat edges, are its weakest parts. These radial edges are designed differently to the insert’s flat edges. They are often placed in the cutting zone and, as a consequence, frequently break first.

These are the issues Sandvik Coromant’s specialists kept in mind while designing a next generation tool that would meet the stringent requirements of a variety of sectors. Crucially, the invention needed to reduce the number of tools, changeovers and tool handling required during manufacturing, for reduced cycle times and improved manufacturing economics.

The result was CoroMill® MH20, a new high-feed milling cutter designed for milling cavities, or pockets, in ISO S, M and P materials.

Opportunity to innovate
The design of CoroMill® MH20 has several innovations. They include a new cutter body material, used for the cylindrical shank bodies, that gives levels of stiffness not seen before in this type of tool. The material minimizes wear and tear during machining and also reduces chip rubbing and coining ― when high stress caused by high cutting forces causes plastic deformation on the insert seat. With this feature, the tip seat remains secure and undeformed which provides better tool life.

Next, we have an alternative to the aforementioned four-edge concept: CoroMill® MH20 is designed with a two-edge insert. With the two-edge concept, machining against a corner or wall will not impact the next edge or leading corner, giving an equal performance per edge. The advantages are greater reliability and protection against wear. The edge line of the insert’s main cutting edge and corner radius are also optimized for further process security.

Another area of innovation is CoroMill® MH20’s insert cutting edge geometry. For the first time in high feed concepts, Sandvik Coromant is introducing dedicated insert geometries for different ISO areas to deliver greater optimized process security and productivity. With CoroMill® MH20, a sloped edge design delivers a gradual and light-cutting action, requiring less power consumption suited to the use of smaller machines.

Sandvik Coromant’s CoroMill® MH20 has exhibited substantially-improved tool life over previous-generation tools for its customers — up to 30% in some cases, although this performance will always differ depending on the material.

Precision machining
One Sandvik Coromant customer, a large machine shop in Canada that specialises in mold and die manufacturing, wished to upgrade its existing tooling setup. The customer had been using a competitor’s tool, which had been suffering from vibrations that made machining processes unpredictable and insecure.

To resolve these issues, the machine shop turned to Sandvik Coromant to test the performance of CoroMill® MH20 against its existing tool. Both tools were used to perform rough pocketing on a workpiece made from H13, a popular chromium hot-work steel known for its high toughness and fatigue resistance, to produce a mold.

Each milling tool measured 25.4 mm (1 inch) and was run at a cutting speed (vc) of 168 m/min (550 surface ft/min). CoroMill® MH20 was run at a slightly higher feed rate with two inserts, because this allowed the depth of cut to be increased by 35%. The parameters were: a feed per tooth (fz) of 1 mm/tooth (0.04 inch/tooth), feed speed (vf) of 5,080 mm/min (200 inch/min) and axial depth of cut (ap) of 0.8 mm (0.031 inch).

The competing tool was run at an fz of 0.63 mm/tooth (0.025 inch/tooth), vf of 4572 mm/min (180 inch/mm) and ap of 0.5 mm (0.020 inch). Both tools were run until they showed signs of flank wear.

Despite the higher cutting parameters, CoroMill® MH20 finished a complete component with no indexing, and a superior surface finish. It exhibited at 50% tool life increase by running for 300 mins, with a 50% cycle time reduction. The competing tool, meanwhile, ran for half the amount of time at 150 min. It required additional indexing because of poor tool life, which further increased the cycle times. The competitor’s insert again suffered from vibrations that caused screws to back out during machining.

By upgrading to CoroMill® MH20, the customer has achieved a significantly improved tool life and more secure, vibration-free machining processes. Even if, as PwC observes, disruption is the only constant in today’s industrial manufacturing environment, new tooling innovations like CoroMill® MH20 support improved tool life and process security. This greatly benefits manufacturers’ competitiveness.

Fewer than 30% of manufacturers have extensively adopted Industry 4.0 technologies, according to responses to a new report. But, manufacturers’ reluctance to go digital might have to change if they are to adapt to an unpredictable future. Here, James Thorpe, global product manager at Sandvik Coromant, the global leader in metal-cutting tools, explains how, by combining advanced software with the correct machine tools, manufacturers can digitalise profitably, and on their own terms.

The Industry 4.0 & Smart Manufacturing Adoption Report by IoT Analytics suggests that the Industry 4.0 technology uptake is still low among manufacturers. Given that the advantages of Industry 4.0 are now so well-understood, why aren’t more manufacturers digitalising their processes?

One perception is that applying Industry 4.0 to existing production setups is expensive when, actually, it doesn’t have to be. Another reason for the slow uptake is that manufacturers see no reason to upgrade their existing tooling set-up and processes. If it isn’t broken, why replace it? Manufacturers in this category may be unsure of how Industry 4.0 fits into their established way of doing things.

The truth is, automated Industry 4.0 technologies can greatly benefit manufacturers’ bottom lines. For instance, Sandvik Coromant has found that a 20% increase in machine utilisation can provide a 10% higher gross profit margin and automated systems can massively increase machine uptime.

Automated equipment can also support the growing trend for machining with limited, or no, human supervision — particularly amid the pandemic. As stated in a recent Pricewaterhouse Coopers (PwC) report, COVID-19: What it means for industrial manufacturers, “For companies vulnerable to a viral outbreak within their ranks, this would be a critical time to explore a proactive deployment of automation technologies.”

Today’s Industry 4.0 technologies, including sensors and machine learning can also be beneficial in minimising the number of production stops. Again, increasing profit. This includes stops needed to replace worn tooling, like drills.

Previously, operators had to rely on manual monitoring to detect wear in machine tools. PwC’s report points towards the Industrial Internet of Things (IIoT) as an alternative. An example of this is Sandvik Coromant’s latest CoroPlus® Machining Insights platform, an expansion of the company’s CoroPlus suite of connectivity software.

Using Machining Insights, CNC machines can connect through Ethernet and transmit information at higher volume than they can currently. This includes manufacturing data to improve workshop efficiency and overall equipment effectiveness (OEE). And this isn’t limited to new machinery. Most machines are connectible to the network, and there are adapters for older machines to make them compatible. In other words, Industry 4.0 can be integrated easily, even with legacy hardware.

Tool technology in practice
As manufacturing becomes increasingly automated, unpredictable tool 
life is more of an issue. In Korea, an automotive manufacturer experienced 
this exact issue and worked with Sandvik Coromant to improve tool life.

The CoroDrill 860-GM is suitable for all applications where hole quality 
is critical. This includes aerospace, general engineering, oil and gas, nuclear 
and renewable power. Its optimised reliability is also proven in automotive 
production, including the drilling of engine blocks, casings, flanges and 
manifolds.

The application used the CoroDrill 860-GM to drill through holes for 
automotive transmission connectors. Overall, eight 8.2 mm (0.32”) 
diameter through holes were drilled into each component that measured 
a depth of 10 mm (0.39”). The previous tool produced 200 components, 
1600 holes in total, with a cutting speed (Vc) of 80m/min (3102 RPM) and
cutting feed (Vf) of 381 mm/min. In comparison, the CoroDrill 860-GM 
produced 2300 components (18400 holes) with a Vc of 100m/min 
(3878 RPM) and Vf of 814 mm/min.

The result was a significantly improved tool life of 1150%, and a productivity 
increase that lowered the overall costs-per-part.

As well as facilitating longer tool life, these tools can deliver increased 
cutting data and therefore enable faster cutting rates. In fact, an 
engineering company in Lancaster, Ohio, US, was able to achieve a 57% 
faster cutting rate when using the CoroDrill 860-GM versus a competitors drill. 
The application used the tool to drill sensor housing components made from 
304 stainless steel — 11 holes in each, 6.6 mm (0.260”) in diameter.

Predictable wear
Machining Insights is designed to give manufacturers greater visibility of machining processes and provide information to identify and eliminate downtime and inefficiency. This includes during periods of largely or fully-automated processes.

Let’s face it, one of the biggest threats to production is unpredictable tool life. For a tool to properly support automated production, limiting continuous, controllable wear and eliminating discontinuous, uncontrollable wear are the keys to success.

Sandvik Coromant’s specialists had this in mind when developing the CoroDrill® 860 with enhanced -GM geometry, a new design solid carbide drill that’s optimised for a wide range of materials and applications, across all industry sectors.

Unique approach to design
For Sandvik Coromant’s specialists, the key to longer tool life is not limited to the amount of time a tool spends in use, but the drill design itself.

The CoroDrill 860-GM has an innovative, polished flute design. The ground-breaking design improves the evacuation of chips and yields greater hole quality, while also helping to reduce heat build-up and cutting forces while drilling. Other key features of the drill’s design include a reinforced core and corner chamfers, edge preparation to remove cutting micro defects and a double margin to enhance drilling stability. The drill’s point is also designed with refined clearance angles and improved surface quality.

Go online
To increase tool life, manufacturers must invest in Industry 4.0 technologies, like Machining Insights, to monitor wear. That said, they must not overlook investing in strong tooling to begin with. Sandvik Coromant’s CoroPlus® Tool Guide simplifies tool selection. By accessing the online application via a web browser and the entering workpiece material and application, users can find the best solid round tool and cutting data for their requirements.

Meanwhile, along with Machining Insights, Sandvik Coromant’s digital machining portfolio includes CoroPlus® Process Control, a process control solution comprising both hardware and software. The solution monitors machines in real-time and automatically acts according to defined rules, rather than just providing an alert. Actions can include stopping the machine in case of a collision, or replacing a worn tool.

There are countless productivity, profit and maintenance advantages available to machine shops that are willing to overcome their reluctance to embrace Industry 4.0. Through the correct use of these technologies, manufacturers can go digital on their own terms — and be within the 30% of manufacturers, cited in IoT Analytics report, that are prepared for an unpredictable future.

Optimised solution to overcome instability, vibration and heavy interruptions in steel turning applications.

Cutting tool and tooling system specialist Sandvik Coromant has introduced its GC4335 insert grade for the turning of steels where unstable conditions or vibration issues prevail. GC4335 is designed to bring about secure and predictable machining, as well as shorter cycle times and better machine utilisation through reduced stoppages and longer insert life. Customers will benefit from an improved process with less risk of insert breakage, as well as reduced cost per component and faster return on investment.

GC4335, which features Inveio coating technology for maximum thermal protection, offers greater steel turning endurance through improved edge-line security in comparison with the p​revious-generation grade, along with greater resistance to flank wear, plastic deformation and crater wear.

“The new GC4335 is particularly suited for uneven forged surfaces, the turning of which can lead to frequent insert changes due to fatigue and failure,” explains Bimal Mazumdar, Product Manager-Turning. “Slowing down an operation to replace a broken insert means less production. When production is slower, fewer parts get completed per cycle and that affects overall profitability.”

Among those set to benefit from the introduction of GC4335 are general engineering shops, as well as automotive OEMs and tier suppliers and subcontractors in the oil and​​ gas sector. Typical components include tubes, valves, crankshafts, differential housings, flanges and rings to list a few.

Underlying reasons behind the performance of GC4335 include a new substrate that is well balanced between reliable toughness and resistance to plastic deformation. In addition, a new alumina coating delivers efficient heat transfer from the cutting zone to act as a heat barrier and the columnar MT-TiCN inner coating offers improved resistance against abrasive wear. A yellow TiN coating on the insert flank allows for easy wear detection.

To highlight the potential gains, an external face-turning application in dry cutting conditions saw GC4335 outperform a competitor insert on unalloyed steel (220 HB), delivering 3647 completed components in comparison with just 1980 (an 84% increase). The time in cut for this finishing operation was two seconds per component, while cutting speed was 145 m/min (475 ft/min), feed rate was 0.4 mm/rev (0.016 in/rev) and depth of cut was 0.35 mm (0.014 in). Equally significant gains are achievable against GC4235, the previous generation insert grade from Sandvik Coromant.

The GC4335 assortment is available in T-Max^® P and CoroTurn^® 107.

New Automation Capabilities Offer Customers More Intelligent Manufacturing

Sandvik Coromant is strengthening its capabilities in Digital Manufacturing by signing a strategic research agreement with PARC, a Xerox company, world-renowned innovation center. PARC will provide Sandvik Coromant with a footprint in Silicon Valley and expert resources for research & development in the field of Digital Manufacturing.

PARC will allocate resources to conduct research & develop technologies within Digital Manufacturing for Sandvik Coromant under the terms of the agreement. Sandvik Coromant will also acquire all Intellectual Property (IP) and technology related to PARC’s software for high-level process planning and automated manufacturing cost estimation for subtractive manufacturing.

“This partnership is a natural step and in line with Sandvik Coromant’s long-term strategy to develop attractive solutions in the field of digital manufacturing and Industry 4.0,” said Magnus Ekbäck, Vice President and Head of Business Development and Digital Machining for Sandvik Coromant. “With this cooperation we will significantly strengthen our capabilities within digital machining.”

“Manufacturing is entering a dynamic new phase as the cyber and physical worlds converge, and the complex and diverse industry needs significant innovation to truly progress,” said PARC CEO Tolga Kurtoglu. “The missing piece for complete design automation and manufacturing of complex products has been the integrated coupling of design and manufacturing, which we have been developing at PARC for many years. We’re pleased to partner with Sandvik Coromant to see these innovations come to life on the global stage.”

PARC has been developing technologies for government agencies and commercial clients in the field of digital manufacturing for almost a decade. Its digital manufacturing suite of technologies helps designers and manufacturers understand real-world manufacturing process constraints during digital product design and identifies potential limitations of a supply chain early in the design phase, ultimately minimizing time-to-market and improving overall product quality.

The strategic research agreement will be governed by a Joint Steering Committee with representatives from both PARC and Sandvik Coromant.