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.

Industry’s first ’all directional turning’ solution offers improved machining flexibility, productivity and tool life.

Cutting tool and tooling system specialist Sandvik Coromant has unveiled a revolutionary new turning concept that offers improved machining flexibility and the potential for significant productivity gains. The company’s PrimeTurning methodology and supporting tools provide manufacturers, particularly in aerospace and automotive sectors, with the industry’s first true ‘all directional turning’ solution.

Unlike conventional turning operations – which have remained largely unchanged for decades – PrimeTurning allows machine shops to complete longitudinal (forward and back), facing and profiling operations with a single tool. The methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This allows for the application of a small entering angle, higher lead angle and the possibility of machining with higher cutting parameters. Furthermore, conventional turning (from part-end to chuck) can be performed using the same tools.

Sandvik Coromant believes that some applications could see productivity increases in excess of 50% through the deployment of PrimeTurning rather than conventional techniques. Some of these improvements are due to the small entering angle and higher lead angle, which creates thinner, wider chips that spread the load and heat away from the nose radius. The result is both increased cutting data and extended tool life. In addition, as cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming (a common and unwanted effect of conventional longitudinal turning). Higher machine utilization due to reduced set-up time and fewer production stops for tool changes also enhances overall productivity.

PrimeTurning will be particularly beneficial to manufacturing industries such as aerospace and automotive where there is a need to perform external turning operations in big batch productions or where multiple set-ups and tool changes are often required.

“Experienced operators know that a small entering angle allows for increased feed rates,” says Håkan Ericksson, Manager of Application Technology at Sandvik Coromant.

“However, in conventional turning they are restricted to using entering angles of around 90° to reach the shoulder and avoid the long, curved chips that a small entering angle characteristically delivers. PrimeTurning solves these problems ​by combining a perfect reach at the shoulder and the application of 25-30° entering angles with excellent chip control and maintained tolerances. This innovation presents countless possibilities to perform turning operations in much more efficient and productive ways. It’s not just a new tool, but a totally n​ew way of turning.”

PrimeTurning is initially supported by the introduction of two dedicated CoroTurn^® Prime turning tools and the PrimeTurning code generator, which supplies optimised programming codes and techniques. CoroTurn Prime inserts have three edges/corners; one for longitudinal turning, one for facing and one for profiling, thus delivering efficient edge utilisation and longer tool life.

Two unique and dedicated inserts are offered: CoroTurn Prime A-type features three 35° corners and is designed for light roughing, finishing and profiling, while CoroTurn Prime B-type with its ultra-strong corners is designed specifically for rough machining. Suitable for ISO P (steel), S (heat-resistant super alloys and titanium) and M (stainless steel) category materials, nine CoroTurn Prime A-type and six CoroTurn Prime B-type inserts are currently available, with expansion to other material​s envisioned for the future. The inserts are supported by 52 variants of tool holder, including Coromant Capto^®​, CoroTurn QS and shanks.​

The PrimeTurning code generator not only ensures maximum output but also process security with suitably adjusted feed rate and entry radius parameters. It creates ISO codes that are compatible with various CNC systems.

Customers set to benefit from co-operation between market leaders

Cutting tool and tooling systems specialist Sandvik Coromant has signed an agreement to become a Premium Partner of leading machine tool manufacturer, DMG MORI. The deal makes Sandvik Coromant the only tooling manufacturer to be named as a DMG MORI Premium Partner, and will serve to further strengthen the relationship between the companies on a global scale. Machine shops around the world will now benefit from the combined knowledge and experience of two market leaders.

As a DMG MORI Premium Partner, Sandvik Coromant will work together with the machine tool builder on initiatives such as open house events, trade show appearances, technical seminars, website collaboration and the DMG MORI Journal. Specifically, the agreement will give users of DMG MORI machines access to turning, parting and grooving, threading, milling, drilling, boring and reaming tools from Sandvik Coromant, as well as tooling systems and the company’s extensive range of knowledge, industry solutions and services.

“This agreement confirms our position as one of our industry’s true premium and forward-looking companies,” says Klas Forsström, Global President of Sandvik Coromant. “As we join forces with a leading machine tool builder, for example on turnkey projects, we take an active role in advancing technology for the industry.”

Sandvik Coromant will equip DMG MORI machines right from the start of each project with a wide range of products, services and know-how. For instance, a customised start-up tool kit and service will be supplied with each NLX series universal lathe and NT turn-mill centre.

Sandvik Coromant will equip DMG MORI machines right from the start of each project with a wide range of products, services and know-how. For instance, a customised start-up tool kit and service will be supplied with each NLX series universal lathe and NT turn-mill centre.

An example of the successful collaboration between Sandvik Coromant and DMG MORI can be seen when the pair recently partnered with Rota Metal, a distributor in Turkey, and its customer, Polat Makina.

Polat, a producer of decanter and separator technologies utilised for wastewater treatment, industrial, mineral and food applications, was ready to make the switch from individual machining to multi-tasking machines. Here, Sandvik Coromant was able to recommend a complete new tooling package based upon the company’s Coromant Capto® modular quick-change tooling concept. The DMG MORI machines included an NTX 2000 with Capto C6 spindle, an NT 5400 with Capto C8 spindle, and an NT 6600 with Capto C8 spindle. Further Sandvik Coromant tools specified to help complete the switch included Silent Tools®, CoroTurn® HP, CoroCut® SL, CoroDrill® 860, CoroTap® 300, CoroChuck® 970 and CoroChuck 930. The end result was reduced machining time, from 2500 to 500 minutes for a finished Duplex stainless steel product. This 80% saving is helping ensure rapid return on the company’s investment.

“Sandvik Coromant did not just supply the tools, they supplied the solution,” says Volkan Polat, deputy general manager of Polat Makina.

GC1130 insert grade now available for use with groove milling tools

Cutting tool and tooling systems specialist Sandvik Coromant has made its high performance steel milling grade, GC1130, available for use with CoroMill® QD and CoroMill 331 groove milling cutters. GC1130, which is the latest Zertivo grade from Sandvik Coromant, delivers high metal removal rates and secure performance levels in both wet and dry machining operations.

Already available for use with CoroMill 390, CoroMill 490 and CoroMill 495 shoulder and chamfer milling systems, this expansion of the application area makes the benefits of Zertivo technology, such as longer tool life and secure machining, available to a wider user profile.

Machine shops can now use grade GC1130 inserts with CoroMill QD for deep and narrow grooving in both external and internal roughing and finishing operations. For additional groove milling requirements, GC1130 inserts can also be applied to CoroMill 331, a multi-purpose side and face milling cutter. This versatile tool is capable of grooving, double half side milling, shoulder milling, face milling, back face milling, gang milling and circular ramping.

In total, GC1130 is now introduced to seven additional product families. Along with CoroMill QD and CoroMill 331, the insert grade is available for use with CoroMill 790 and T-Max long edge (shoulder milling), CoroMill Century (face milling), CoroMill 170 and CoroMill 176 (gear milling).

“Issues such as flaking, abrupt chipping and thermal cracks are commonly encountered when milling materials in the ISO P application area, especially when faced with unfavorable tool paths, deep cavities or when using coolant.” says Björn Ericsson, Project Manager. “We have developed GC1130 to help machine shops overcome the consequential effects of reduced insert life and unstable production.”

Manufactured using Zertivo – a PVD production technology that is designed to enhance the grade’s advantages – GC1130 offers high edge-line security and reduced flaking. In addition, a high-Cr content fine-grain substrate delivers high resistance to thermal cracks, helping ensure long and reliable tool life.

Cutting tool and tooling systems specialist Sandvik Coromant has unveiled its CoroPlus suite of IIOT solutions aimed at helping manufacturers prepare for Industry 4.0. The concept is designed specifically to improve the control of productivity and costs through a combination of connected machining and access to manufacturing data and expert knowledge.

CoroPlus is the umbrella name or a new platform of connected tools and software; essentially comprising technologies that can send and/or receive data. The concept makes it possible to reduce data waste and improve manufacturing processes, from pre- to post-machining, through the use of connected technology and machining knowledge from Sandvik Coromant.

“Users not only get access to Sandvik Coromant product and application data through connected software and hardware, but with sensor-equipped tools they can adjust, control and monitor machining performance in real time,” says Göran Näslund, Head of Digital Machining. “The entire machine shop can be controlled via accurate on-site data dashboards, through the cloud and via integration with the user’s software and machine environment. CoroPlus connects into existing software environments through open APIs, offering two-way connectivity and accurate data quality.”

The principal benefit for production managers is that CoroPlus makes it possible to optimise manufacturing through better understanding and insight into what’s happening in the workshops and machining environment, on either a micro or macro level. From a CAM programmer’s perspective, connection with accurate tool and application data means that recommendations can be adapted to specific tasks. There are also advantages for operators as machining processes can be monitored remotely. Furthermore, specific sensor-equipped tools can be controlled to ensure that breakages are avoided and performance is secured, with data intelligence collected live throughout the machining process.

The offer currently comprises dashboard solutions, software solutions in CoroPlus ToolGuide and Adveon Tool Library, as well as Silent Tools+ and CoroBore+ cutting tools and Promos 3+ machine monitoring IoT system.

“With CoroPlus we are partnering with machining tool builders, cloud suppliers and network companies,” explains Göran. “In this way we can help users capitalise on new technology developments. Our role is to increase productivity and flexibility through value-creating technological advancements in digital machining.”

Ultimately, CoroPlus makes it possible for manufacturers to take the next step in industrial evolution by making use of new cyber-physical systems – meeting industry’s needs now and moving forward.

The new CoroMill 316 generation of exchangeable-head milling cutters from Sandvik Coromant enhances the company’s established Solid Round Tools portfolio by bringing higher levels of versatility and productivity to machining operations in ISO P (steel) and ISO M (stainless steel) materials. Further benefits include high reliability in almost all applications, along with enhanced tool life and a silent machining process.

CoroMill 316 is suitable for all general milling operations, including high-feed face milling, slot milling, helical interpolation, shoulder milling, profile milling and chamfer milling. The exchangeable heads allow users to easily and accurately switch between various operations, creating end mills with optimised radius variation, teeth frequency, geometry and grade. Beyond steel and stainless steel, the tools can also be used successfully on ISO K (cast iron) and ISO S (heat resistant super alloys) materials.

“The latest generation of CoroMill 316 adds a longer cutting length to its list of attributes, delivering even greater flexibility for machine shops,” says Tiziana Pro, Product Manager Solid End Mills at Sandvik Coromant. “Specific operations to benefit includes those that demand higher axial depth, up to 1.2 x Dc, as well as where high stability and vibration suppression are required. In particular, the combination of the modular Coromant EH system and CoroMill 316 provides a number of solutions for all types of machines and user challenges.”

Manufacturers should choose Coromant EH as the preferred rotating modular interface for applications up to 32 mm (1.256 inch) in diameter. Integrated machine adaptors with EH coupling are recommended for small interfaces where gauge line and swing diameter are critical (BT30, SK40, HSK40/50/63, ER, DTH), as well as different shank types in long overhang applications up to 35 mm (1.38 inch) diameter.

CoroMill 316 is part of the extensive Solid Rounds Tools offer from Sandvik Coromant, which today includes more than 10,000 standard products to cover all applications within the areas of solid carbide drilling, milling, tapping, reaming and threading.

Solid Round Tools are purpose-designed to support workflow, efficiency and productivity, with each cutter positioned within three product categories: versatile, optimised and customised. Versatile solutions are performance-oriented tools based on maximising flexibility and cost efficiency for the customer, while optimised solutions comprise a unique line of refined tools for specific needs where extreme efficiency, reliability and durability are paramount. Customised solutions are designed individually to meet the highest performance demands.

Sandvik Coromant is now offering tooling dedicated to the challenging operation of machining valve seat pockets in oil and gas applications. Comprised of a combination of an elliptical Silent Tools adaptor and CoroTurn® SL cutting head, this solution is designed to overcome prevalent issues such as narrow flow bore diameters, vibration tendencies and long overhangs.

The challenges of machining valve seat pockets in the oil and gas industry encouraged Sandvik Coromant to create a tool with extended radial reach that offered high levels of security, repeatability and performance into this demanding back-turning operation. With elliptical Silent Tools adaptors designed to reach deep seats, and CoroTurn SL cutting heads featuring a lightweight structure, a stable tooling configuration minimises vibration and offers extended reach in both roughing and finishing operations.

“The thicker back-end base and elliptical shape of the adaptor is purposefully designed to gain access to the seat pocket through the narrow flow bore diameter,” says Åke Axner, Global Product Manager for Machine Integration. “In addition, the use of CoroTurn SL cutting heads gives users the potential to reach maximum cutting depth while Coromant Capto tool holders are recommended for stability and precision.”

A recent back-turning trial in cladded Inconel 625 highlights how the solution can eliminate vibration and promote surface quality. Using an elliptical Silent Tools adaptor, 25 mm CoroTurn SL cutting head and Coromant Capto C6 tool holder for one roughing and two finishing cuts, the final pass witnessed a surface finish of 0.2Ra (9 cla) achieved at a cutting speed of 27 m/min (90 ft/min), feed rate of 0.02 mm/rev (0.008 in/rev) and 0.1 mm (0.004 in) depth of cut.

The elliptical adaptors are part of the Silent Tools standard assortment and are available within a 24 hour delivery time if required.

Steel milling grade offers greater security and productivity

Machine shops faced with identifying ways of achieving secure machining with long and predictable insert life in steel milling operations can turn to GC1130, an insert made with the Zertivo, a unique production technology from Sandvik Coromant. GC1130 helps to overcome challenging machining conditions with a clean and intact edge, delivering high metal removal rates and performance levels in both wet and dry machining operations. The grade is offered as the first choice for shoulder milling cutters, CoroMill 390 and CoroMill 490 and chamfer cutter, CoroMill 495.

Flaking, abrupt chipping and thermal cracks are common issues encountered when milling materials in steel applications, especially when faced with unfavourable tool paths and deep cavities or when using coolant. GC1130 has been specifically developed to help production engineers combat the subsequent unwanted effects of short insert tool life and unstable production. Manufactured with Zertivo, a unique production technology that helps amplify the grade’s benefits offering peace-of-mind through greater edge-line security and reduced flaking. Furthermore, a high-Cr content fine-grain substrate delivers high resistance to thermal cracks generated as a result of temperature fluctuations during machining, helping to ensure long and reliable tool life.

According to Mikael Eiritz, product manager for milling grades at Sandvik Coromant, “The choice of insert geometry and grade is just as important as the choice of tool when looking for secure machining. The tool and insert together is what contributes to the overall performance in an operation. Many times, when using grade GC1130, customers can move from one component to the next without having to stop production. That saves them time and money.”

When repeated shoulder milling is required, the combination of GC1130 with CoroMill 490 provides a suitably light cutting action and smooth profile that can efficiently reduce the need for a finishing operation. Also available for the CoroMill 390, this grade is best when multiple component features are required. Bringing an added dimension of security and predictability to machining in challenging conditions, the assortment includes many different types of tools and a wide selection of corner radii. Applications such as shoulder milling, linear and helical ramping, turn-milling, deep shoulder milling, edging and pocketing can be performed.

In applications where trouble-free chamfering in various steel types is required, pairing CG1130 with CoroMill 495 reduces downtime and allows for higher machine utilization. Along with the chamfering of holes and edges, typical applications include back chamfers, welding preparation and deburring.

Product manager for shoulder milling at Sandvik Coromant, Thomas Wikgren, states, “Greater process security, productivity and tool life are all within reach with GC1130. At the end of the day, our customers are looking for a reliable tool and insert combination that will help them achieve a lower cost per component.”

CoroCut QD inserts in sizes 1, 1.2 and 1.5 mm with internal coolant provide material savings

When material savings is a requirement due to machining expensive materials, large batch productions, or both, it is essential to use the thinnest insert width possible. CoroCut QD dedicated parting off and deep grooving tools are now available in smaller insert widths with internal high-pressure coolant to help customers realize production efficiency.

Realized material savings

Considered a “hidden machining cost,” component material waste is an often-overlooked production expense. Wider insert blades cut away more material than necessary during each parting off operation with the excess material ending up in the chip bin. Using a thinner insert blade not only wastes less material but also allows for more parts per bar when parting off using a bar feeder. Realizing this material savings is especially important for those who machine components made of expensive materials, such as heat resistant super alloys (HRSAs) like Inconel, titanium and cobalt chrome. When working with these high-priced materials in higher volumes, using a thicker insert blade can be costly.

Additional benefits

For smaller insert widths, insert handling is easily accomplished with the use of the insert cam key. Accompanied with each CoroCut QD, the cam key allows the user to leave the finger of the blade in the open position allowing for use of both hands for insert positioning. With the turn of the cam key, the new insert clamp design offers improved rigidity for process security. CoroCut QD toolholders are made using the same improved tool steel as the larger width CoroCut QD, resulting in 12% higher tensile strength.

According to Staffan Lundström, Parting and Grooving Product Specialist at Sandvik Coromant, “As the only product currently on the market that offers over and under coolant in a tool this thin, the CoroCut QD inserts in 1 mm, 1.2 mm and 1.5 mm work well for deeper cuts and larger diameters and for all materials, especially HRSAs.” Parting and Grooving Specialist Scott Lewis adds, “Shops that solely focus on tool costs can be missing the big picture. When a tool costs you more in material waste over time, especially expensive materials, the overall cost to machine a component can be much higher than expected.”

Increased machine utilization for effective steel turning

For longitudinal and face turning, Sandvik Coromant introduces the new CoroTurn 300 for higher component quality, increased handling efficiency and longer tool life in steel turning operations. Available immediately, the CoroTurn 300 features stable insert clamping, as well as eight-edged inserts for the high chip control, tool life and surface finish.

Stable insert clamping for the CoroTurn 300 is made possible through the patented iLock interface. This system securely locks the insert in place to prevent cutting forces from affecting the tool position. iLock provides tool accuracy within ±0.05 mm (.002 inch) giving the operator indexing repeatability for a better surface finish and increased tool life.

The eight-edged inserts for the CoroTurn 300 are available in grades GC4325 and GC4315 featuring Inveio coating, a uni-directional crystal orientation for high wear resistance and long tool life. The unique insert design has excellent chip breaking capabilities and less carbide per edge, which reduces the impact on our environment with less material to waste or recycle. Plus more edges allows for better inventory control.

Another way the CoroTurn 300 offers chip breaking capabilities is through high-precision (HP) over and under coolant. Coolant from above controls the chip breaking for secure machining while under coolant controls the temperature for long and predictable tool life. Other features of the tool are the Coromant Capto interface in a variety of sizes and the Quick Start (QS) shanks which enable quick tool changes and easy coolant connections for maximized production time.

John Winter, turning product specialist for Sandvik Coromant, says, “The CoroTurn 300 integrates the latest advances in iLock, Inveio, and high-precision coolant technology to take steel turning into the next century using an insert with eight, 80 degree cutting edges. This is the perfect tool for high volume outer diameter (OD) steel turning applications where tool life and process security is a must.” Application specialist for general turning, Stefan Wernh, also states, “CoroTurn 300 is designed to achieve outstanding performance in a turning process and the handling efficiency maximizes the machine utilization.”