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Manufacturing Capacity Doubled

Manufacturing Capacity Doubled

British luxury watch manufacturer Bremont made the most of Sandvik Coromant and DMG MORI’s strategic partnership as it introduced a turnkey manufacturing cell to double capacity at its factory.

The NTX 1000, a state-of-the-art 5-axis machining center from DMG MORI, was is equipped with tool packages from Sandvik Coromant.

​​​Luxury watchmaker Bremont Watch Company is a true British manufacturing success story. Founded by brothers Nick and Giles English in 2002, the company specialises in the manufacture of certified chronometers for the aviation sector. These watches are assembled, as well as shock and quality tested, at the manufacturer’s dedicated headquarters in Henley-on-Thames, Oxfordshire, UK. Production of the main components, such as stainless steel backs and casings, takes place just a few minutes’ drive away.

High demand and the launch of six new watch designs meant that Bremont’s production capacity had to be increased. To achieve this, the company purchased an NTX 1000, a state-of-the-art 5-axis machining centre from DMG MORI, which is equipped with tool packages from Sandvik Coromant.

The project was six months in the making, explains Mathew Bates, a machine tool investment specialist from Sandvik Coromant’s UK Machine Tool Solutions team. “From the beginning, the objective was to deliver a ‘right first time’ solution,” explains Bates. “We wanted Bremont to be able to use the new system straight away.”

Close collaboration with application technicians from DMG MORI was needed, with regard to the selection of suitable tools. 

“We knew that we had to produce six new watches,” says Bates. “As soon as the drawings were ready we met with specialists from DMG MORI to compile a list of standard tools and to determine which special tools would be needed.”

Integrated Automation for 24/7 Operation

The DMG MORI NTX 1000 is equipped with a magazine for 38  Coromant Capto tools, with the option of expanding the capacity up to 76 tools. The turn and mill machine is suitable for turning and high-speed milling in five axes, simultaneously. 

Thanks to the bar loader, the machine produces the different stainless steel components around the clock without any operator intervention. 

Everything from a Single Source—Tools, Machine, Automation and Programming

Even before the installation of the machine, Frederick Shortt, application technician at DMG MORI, and his development team created and simulated the numerical control (NC) programs with the Vericut computer-aided manufacture (CAM) system.

“Together with Sandvik Coromant we optimised all programs in such a way that as few tools as possible are needed,” says Shortt.

In other words, Bremont only bought what they really needed. As this all took place before the installation, so Bremont was able to start producing from day one.

“This joint optimisation meant that any teething problems were reduced to a minimum and the investment quickly paid off for Bremont,” explains James Rhys-Davies, Strategic Relations Director, Northern Europe at Sandvik Coromant.

“The call for such turnkey solutions will increase steadily. Although the preliminary costs are sometimes a little higher, the benefits of a fast return on investment (ROI) and maximisation of machine availability make such turnkey production cells a very attractive option, as cost per part is generally much lower.”

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Sandvik Coromant Appoints New President

Sandvik Coromant Appoints New President

Sandvik Coromant has announced Helen Blomqvist as its new President, succeeding Nadine Crauwels.

As president, Helen will be responsible for enhancing Sandvik Coromant’s leading position in manufacturing tools and machining solutions and sharing the knowledge that drives the manufacturing industry forward. Helen will report to the newly appointed President of Sandvik Machining Solutions, Nadine Crauwels, and will be a member of the Sandvik Machining Solutions Management Team. She starts her new position on 1 December 2020.

Blomqvist has a solid background with Sandvik Coromant and joined the company in 2003 as a research engineer. In her 17 years, she has held various managerial positions in Product Management and R&D, as well as in sales — having been the General Manager for Sales Area North Europe. She holds two patents and in 2018, she was awarded Sandvik Coromant Leader of the Year.

Blomqvist is a Swedish national and holds a PhD in Structural Chemistry from Stockholm University.

“I am pleased and honoured to have the opportunity to lead Sandvik Coromant, a company with a fantastic position for products and solutions that are adding value to our customers. I look forward to working with Sandvik Coromant’s management team, employees and partners to continue to develop our offering, our innovation power and to implement our strategy to lead the industry forward and shape the future of the manufacturing industry. My focus will be to strengthen our role as market leader.” says Blomqvist.

Sandvik Coromant owns over 3,100 patents worldwide, employs 7,00 members of staff and is represented in 150 countries. For more information on Sandvik Coromant, please visit the Sandvik Coromant website for the latest news.

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What Is Successful Milling?

What is Successful Milling?

Milling 101: What are the considerations when it comes to milling operations, and how can operators reduce vibration in milling? Read on. Article by Sandvik Coromant.

Milling has been evolved into a method that machines a very broad range of operations. In addition to all the conventional applications, milling is a strong alternative for producing holes, threads, cavities and surfaces that used to be turned, drilled or tapped.

There are different types of milling operations. They are: 

  • Shoulder milling
  • Face milling
  • Profile milling
  • Groove milling and parting off
  • Chamfer milling
  • Turn milling
  • Gear machining
  • Holes and cavities/ pocketing

The following are the initial considerations for milling operations:

  1. The milled configuration

The features to be milled have to be carefully considered. These can be located deep, requiring extended tooling, or contain interruptions and inclusions.

  1. The component

Workpiece surfaces can be demanding, with cast skin or forging scale. In cases of bad rigidity, caused by thin sections or weak clamping, dedicated tooling and strategies have to be used. The workpiece material and its machinability must also be analyzed to establish optimal cutting data.

  1. The machine

The choice of milling method will determine the type of machine needed. Face/shoulder or slot milling can be performed in 3-axis machines, while milling 3D profiles require alternatively 4- or 5-axis machines.

Turning centres today often have milling capability due to driven tools, and machining centres often have turning capability. CAM developments mean that 5-axis machines are increasingly common. They offer increased flexibility, but stability can be a limitation.

How to Reduce Vibration in Milling

Milling vibration can arise due to limitations in the cutting tool, the holding tool, the machine, the workpiece or the fixture. To reduce vibration, there are some strategies to consider.

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A Drill For All Materials

A Drill for All Materials

It’s said that life is a marathon, not a sprint. For automotive manufacturers, longer lasting tooling solutions are integral to more profitable production—but, often, manufacturers see little reason to change their existing tool set-up. In this article, James Thorpe, global product manager at Sandvik Coromant, explains why the benefits of longer-lasting tools shouldn’t be underestimated, particularly for reducing costs-per-part or increasing overall output.

A Drill for All Materials

Unpredictable tool life is one of the biggest threats in mass automotive production, particularly as its operations are so highly-automated and use some of the world’s most advanced robotics and automation systems. Downtime is time-consuming, disrupts production and is also expensive, so it goes without saying that tool failures should be avoided at all costs. 

In some instances, manufacturers set the tool change interval to less than the maximum tool life. This approach is normally preferred because material variations in automotive components are minimal. It follows that the tool changes should be predictable, and safer, than trying to extend the tool life to manufacture a few more components. 

Multi-material Drilling

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 also the drill design itself. This approach led to the development of the CoroDrill 860 with enhanced -GM geometry, a new design solid carbide drill that’s optimized for a wide range of materials and applications, across all industry sectors. 

For the CoroDrill 860-GM, Sandvik Coromant applied its machine tooling and metal cutting expertise to develop a new grade, a unique fine-grained carbide substrate known as X1BM. The fine-grained carbide is imbued with increased hardness while maintaining toughness.

Furthermore, the drill is tip-coated with a multi-layer physical vapor deposition (PVD) thin film coating. This is key to improving the drill’s productivity and delivering a consistent tool life across a variety of materials. The result is a tool with excellent stability, machining security and improved tool life when machining cast iron, steel, stainless steel, hardened steels and non-ferrous metals.

Assessing Tool Life

A better way to assess tool life is by measuring the amount of material removed. To aid productivity, the CoroDrill 860-GM has an innovative, polished flute design that improves the evacuation of chips and yields greater hole quality. This also helps to reduce heat build-up in the tool, and further benefits are high core strength and reduced cutting forces while drilling.

The 860-GM forms part of Sandvik Coromant’s CoroDrill range of solid carbide drills. They are designed not only for optimized performance but also versatility, which means they can be deployed in a variety of applications and materials across multiple industries.

This includes use with the following material groups: ISO-P, the largest material group in metal cutting that ranges from unalloyed to high-alloyed material; ISO-M that includes difficult-to-cut stainless steels, austenitic steels and duplex steels; ISO-K grey, nodular and compacted graphite cast iron; ISO-H steels with a Rockwell hardness of between 45-65 HRc; and ISO-N for softer, non-ferrous materials such as aluminium, copper and brass. 

Advanced Geometry

As mentioned, the CoroDrill 860-GM has an enhanced design, but what exactly does this entail? Much of this relates to the design of the drill itself that includes an advanced optimized point and flute geometry, reinforced core and corner chamfers, edge preparation to remove cutting edge 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. 

Overall, these design features stabilise the drill, reduce entry and exit burr and improve the hole tolerance, finish and straightness. The drill also gives stable wear progression and delivers excellent hole accuracy. 

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Sandvik Coromant Joins Forces With Microsoft To Shape The Future Of Manufacturing

Sandvik Coromant Joins Forces With Microsoft To Shape The Future Of Manufacturing

Sandvik Coromant has embarked on a unique venture with Microsoft to drive forward the development and digitalisation of the manufacturing industry. Combining Sandvik Coromant’s expertise in machining with technical solutions from Microsoft, the collaboration will seek to link up parts of the production chain to create solutions for the next generation of manufacturing. The contract also includes an acceleration of the internal digitalisation network for Sandvik Coromant.

​Sandvik Coromant’s CoroPlus offering, developed in part with Microsoft, is based on Azure IoT Suite, Cortana Intelligence Suite and Dynamics 365 for Field Service. Among other things, the offering connects people, machines, tools and data on a single platform to offer Sandvik Coromant’s customers a better basis for decision making, and provides an overview of the various developments in the manufacturing process. This can enable savings, for example, by reducing machine downtimes.

“We see this collaboration with Microsoft as key to the success of our digital strategy. We have a historic relationship with them and look forward to continuing our journey, creating value by working together to develop and implement solutions for the manufacturing industry to guarantee efficiency, sustainability and growth. This unique partnership represents a new way for our companies to work together more closely to develop our competence,” explained Nadine Crauwels, President of Sandvik Coromant.

One unique aspect of Sandvik Coromant’s CoroPlus offering is that data is not only gathered at machine level to adjust equipment, notify technicians about maintenance requirements and warn managers about potential problems. Data is also gathered at tool level, which means that the customer’s industrial tool becomes “smart” and can be adapted and adjusted at any time for efficient use and to prevent production stoppages.

The partnership with Microsoft adopts an integrated approach to digitising the data, expertise and experience used on a daily basis by Sandvik Coromant to guide their customers, and will serve as an additional tool to facilitate streamlining of production.

The new joint venture between Sandvik Coromant and Microsoft gets under way in the first quarter of 2020 and will involve operations both in Sweden and abroad.​​​

 

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Collet For CoroChuck 930 Maximises Pull-Out Prevention

Collet For CoroChuck 930 Maximises Pull-Out Prevention

Sandvik Coromant has introduced a new collet for its CoroChuck 930 high-precision hydraulic chuck. Designed to suit Weldon shanks, the new collet features a mechanical locking interface to prevent tool pull-out or movement when producing expensive components and/or machining with challenging cutting data.

“Being 100 percent assured of zero pull-out for Weldon shanks when producing high value-added parts, such as aerospace frame and engine components, is paramount in the highly competitive manufacturing arena,” says Mats Backman Global Product Manager at Sandvik Coromant. “Production engineers and managers are under constant pressure to minimise scrap and maximise bottom-line profitability. These thoughts were the driver for developing the new collet.”

The mechanical locking interface acts between the collet and chuck, and between the collet and shank. Having confidence in no pull-out when both collet and chuck are locked enables increased productivity in heavy-duty applications. Further benefits include easy assembly into CoroChuck 930 chucks, both slender and HD versions, while high run-out accuracy is assured with cylindrical clamping of Weldon shanks. In addition, coolant supply through the collet provides secure and reliable coolant delivery to the tool.

Ultimately, this new solution will benefit any machine shop seeking trouble-free machining in heavy applications. No pull-out or tool movement protects against the potentially sizable cost of reworking or scrapping an expensive component. Pull-out effectively changes the gauge length of the tool mid-cut, leading to the generation of features with incorrect dimensions or crash marks.

To provide an example of the potential gains on offer, a customer case trial saw CoroChuck 930 (featuring the new collet) used for a milling operation on a CNC turn-mill machine. The objective was to produce a twin-screw from 42CrMo4 alloy steel. At cutting data of 3220 rpm spindle speed, 1500 mm/min (590 in/min) feed speed, 10 mm (0.394 inch) axial depth of cut (nominal), and 20 mm (0.787 inch) radial depth of cut, the mechanical locking interface generated a stable process with no pull-out. In addition, productivity increased due to longer tool life.

 

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Sandvik Coromant Connected Driven Tool Holder Maximises Machine Utilisation

Sandvik Coromant Connected Driven Tool Holder Maximises Machine Utilisation

Sandvik Coromant is set to boost the utilisation of turning machines and turret-based multi-task machine tools fitted with driven tool holders. Part of the CoroPlus digital machining offer, the company’s Coromant Capto DTH Plus solution minimises costly downtime due to breakages by alerting an operator to the need to service an individual driven tool holder. This enables manufacturers to achieve maximum machine tool productivity and output through predictive maintenance as well as offering fast tool changes in applications using driven tools.

Sandvik Coromant is introducing the new product to solve a common problem for many manufacturers—knowing the optimum time to service their equipment while avoiding the likelihood of tool holder breakage. Outside a planned maintenance schedule, an operator could be running a tool holder in an environment that risks costly damage to equipment, resulting in machining failures and unplanned stops in production.

Developed to complement the Coromant Capto quick-change tooling concept from Sandvik Coromant, the new driven tool holder solution uses sensors to gather data and transmits them via Bluetooth, making predictive maintenance of the holder possible. Thanks to quick-change functionality, the time an operator needs to spend on measuring, set-up, and tool change is kept to a minimum. Also, because the driven tool holders are equipped with Coromant Capto coupling, the solution enables operators to make use of an extensive range of high-performance cutting tools.

The software application included in the new offer provides operators with real-time information – such as the vibration level of the holder—making live monitoring of the spindle possible, while also monitoring the temperature within the tool holder. Other data delivered through the sensors include RPM and direction of rotation, minimising the chances of exceeding the driven tool holder’s limits, and current and historical information about a particular tool. Also provided is data on the location of a driven tool holder, including the specific factory, machine name, turret and station number.

 

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Sandvik Coromant Drills Designed For Aerospace Materials

Sandvik Coromant Drills Designed For Aerospace Materials

Sandvik Coromant has unveiled two new solid carbide drills designed to improve consistency and performance during hole-making operations on workpieces made from challenging aerospace materials such as heat-resistant super alloys (HRSAs), titanium alloys and composites.

The new CoroDrill 860 solid carbide drill with -SM geometry has been developed to provide robust process security, high hole integrity and excellent tool life, making it the first choice for safeguarding quality when performing hole making in ISO S materials like HRSAs, which include Inconel, Waspalloy, Hastelloy and Udimet.

A new grade, 1210, which also features a new coating, is available for Sandvik Coromant’s CoroDrill 860 solid carbide drill with -SM geometry that is designed to ensure a major reduction in flank wear compared with existing solutions. The result is a consistent and reliable cutting edge, which in turn delivers excellent dimensional accuracy and better finished hole tolerance. For this reason, the drill is also ideal for unmanned production, where users can expect to see a significant reduction in component scrap rates. Moreover, overall cost-per-hole will be reduced.

Key aerospace applications where the CoroDrill 860 solid carbide drill with -SM geometry will excel are set to include bosses and scallop/flange face features on casings, as well other features on low-pressure/high-pressure turbine disks and blisks. The assortment, which features internal coolant capability throughout, extends from 2xD to 5xD, in diameters from 3mm to 16mm (0.118in to 0.63in).

Also released is the CoroDrill 863 solid carbide drill with -O geometry, an optimised solution for composite aerospace workpieces. Offering excellent tool life and very high hole integrity, the substrate is based on a new grade, O1AD, for improved wear resistance. A high axial rake angle is included for reduced delamination in unidirectional CFRP (carbon fibre reinforced plastic).

Tool life is improved significantly when using the CoroDrill 863 solid carbide drill with -O geometry, with increases in material drilled often measured in metres. Fewer tool changes are therefore a further benefit of using this repeatable and reliable drill. Typical composite parts set to benefit will include aircraft frames, wingboxes, fuselage sections, stabilizers, floor beams and flaps. The assortment is available from 4xD to 5xD, in diameters from 3mm to 10mm (0.118in to 0.393in).

 

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Sandvik Coromant Launches Indexable Drill For 7xD Hole Depth

Sandvik Coromant Launches Indexable Drill for 7xD Hole Depth

The CoroDrill DS20 from cutting tool and tooling system specialist Sandvik Coromant is the first indexable drill concept capable of producing hole depths up to 7xD. The drill, which includes completely new designs for both the body and inserts, provides users with reliable, predicatable chip control and outstanding penetration rates in all 4-7xD applications.

Replacing the existing CoroDrill 880 and CoroDrill 881 tools, 4-5xD CoroDrill DS20 indexable drills provide tool life improvements of up to 25 percent and productivity gains up to 10 percent, depending on workpiece material. The 6-7xD variants represent an entirely new capability range of indexable drills from Sandvik Coromant. To complement the introduction, the company is releasing a new Modular Drilling Interface (MDI) that acts as a coupling between the drill and adaptor. Available in Coromant Capto and HSK shank types, the MDI provides high precision, excellent centring capabilities and reduced tool inventory.

CoroDrill DS20 indexable drills are both versatile and cost-efficient, increasing tool life and productivity in nearly all workpiece materials compared with current best-in-class concepts. No pilot drilling is needed.

“Amongst the most important factors when drilling to depths of more than 5xD is controlled cutting forces, secure chip evacuation and high centring capabilities,” explained Håkan Carlberg, Senior R&D engineer, Indexable drilling at Sandvik Coromant. “Going from a 5xD to a 7xD drill, the theoretical difficulty increases approximately three-fold due to an increased inclination to bend. Designing a CoroDrill DS20 7xD drill requires careful consideration for around 50 parameters that all depend on each other. The outcome is improved process security through lower forces and lighter cutting, particularly at entry. In turn, users achieve lower cost per hole, the ability to drill deeper and reduced sound levels.”

The drill body is strong and fatigue-resistant with higher levels of stiffness than ever achieved before, while chip flute shapes are individually designed for each drill size and insert. This combination of factors leads to less vibration, predictable wear patterns and increased tool life. In addition, next-generation ‘double-step’ technology reduces entry cutting forces by up to 75 percent compared with CoroDrill 880 tools to improve centring capabilities. Strong insert design and bulk strength provide extra toughness, with four true cutting edges provided on both centre and peripheral inserts.

Regarding the new MDI, double centring with high fitting accuracy enables good run-out precision and optimal repeatability. Here, flange and surface contact between the drill body and nut provides increased stability and promotes hole quality. One size can be used for several drill diameters.

CoroDrill DS20 indexable drills are available from 15mm to 65mm in diameter with a selection of shank types, insert sizes, grades and geometries to suit all material types and applications, including those found across the general engineering, automotive, oil and gas, pump and valve, and aerospace sectors.

 

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Sandvik Coromant To Showcase Digital Solutions For Machining Processes At EMO 2019

Sandvik Coromant To Showcase Digital Solutions For Machining Processes At EMO 2019

Sandvik Coromant will be presenting its latest digital solutions for machining processes and efficient connected manufacturing at EMO Hannover 2019 in Germany. True to the company’s mantra of ‘Shaping the future together’, innovations around digital machining and Industry 4.0 are set to be the focus of its booth at the show.

Of course, hardware in the shape of the latest cutting tool and tooling innovations will also be in the spotlight. Chief amongst the latest products making the transition from development lab to commercial availability will be a revolutionary, easy-to-use solution for efficient and reliable drilling. This breakthrough tool offers unprecedented performance at low cost, while simultaneously delivering consistent hole diameters at lower noise levels than existing generation products. The drill will be officially launched at the booth, where visitors will be the first to discover more. The new-generation lightweight CoroMill 390 milling cutter, produced by additive manufacturing, will also be featured.

Beyond the tooling offer being showcased at EMO, the company’s digital solutions enable the interconnection of design, planning and metal cutting, as well as effective process analysis and advancements. The Various CoroPlus digital machining solutions offer different ways to integrate manufacturing intelligence into a machine shop, resulting in optimised processes and fact-based improvement decisions.

One of the highlights at the booth will be the upgraded CoroPlus ToolPath software for PrimeTurning, which now provides the option to import CAD models and create 3D simulations with collision detection.

Following this holistic approach, Sandvik Coromant will also present a new solution that enables sensor-equipped tools, such as the Silent Tools Plus solution, to send data directly to the machine. In this way, machining processes can be monitored and controlled in real time.

Another offer from the CoroPlus portfolio is the CoroPlus ToolGuide, which provides precise tool recommendations and cutting data based on customer specifics, such as workpiece material and application type. The latest addition includes an update with recommendations for boring tools and cutting data.

The newest addition to the Sandvik Coromant collection of apps is the Tool Wear Analyzer app. Whenever a manufacturer is unsure of the cause of an unexpected tool wear, they can simply use their phone to take a picture of the wear and easily compare it with wear types in a repository of images. The app also allows the user to measure the wear and save it or share it with a colleague. The app works best if you use a microscope attached to the phone.

Sandvik Coromant will be at Hall 5 Booth B06.

 

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