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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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Sandvik Coromant’s CoroBore 825 Damped Fine-Boring Tool Improves Security And Productivity

Sandvik Coromant’s CoroBore 825 Damped Fine-Boring Tool Improves Security And Productivity

Sandvik Coromant’s new generation CoroBore 825 damped fine-boring tool makes use of Silent Tools technology, with dampers dimensioned specifically to suit every adaptor size in the assortment and deliver maximum performance for the user. This solution not only elevates process security where vibration issues are frequently encountered—such as when machining with long overhangs—it improves productivity as cutting data can be increased substantially.

Amongst the principal differences in the latest generation tool is the change of boring head material, from steel to aluminium. In addition, the head has been shortened so that the damper comes closer to the cutting edge, which is beneficial for process stability.

“Internal channels are utilised to deliver coolant directly to the cutting edge, which is another factor that contributes to improved surface finish, higher penetration rates and greater process security,” said Jenny Nilsson, Global Product Manager at Sandvik Coromant. “The new generation of tools will provide optimum performance and stability with one standard adaptive item on the machine tool side – to bridge the tool into a steep taper, HSK or Coromant Capto spindle. Further extensions will reduce stability and performance.”

The CoroTurn insert carriers for the new tools have entering angles at 92-95 deg. This design increases stability due to reduced tool assembly deflection, making it possible to approach the bottom of a blind hole without engaging a bigger part of the cutting edge.

CoroBore 825 is ideal for all fine-boring applications, covering diameters from 19 to 167mm, while a new assortment of cartridges can be utilised for back-boring applications, where the same internal coolant flow to the cutting edge is offered as with conventional boring.

 

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Sandvik Coromant Releases New Insert Geometries For CoroMill 331

Sandvik Coromant Releases New Insert Geometries for CoroMill 331

Introduced for CoroMill 331, Sandvik Coromant’s -M30 geometry is designed to optimise the groove milling of steel and cast iron automotive parts. Available for size 11 inserts offering radius dimensions from 1.5mm to 3mm, -M30 geometry is defined by its light cutting action. This tough geometry is particularly beneficial when machine shops want to boost security in weak set-up or long overhang applications, where it provides reliability and increased competitiveness. Grade availability includes GC1130, GC1020, GC3040 and the latest GC4330 steel milling grade.

Also launched is -L50 geometry, which is aimed at aerospace component machining, as well as parts in the oil and gas industry. Offered on size 11 inserts with radius dimensions from 3mm to 6.3mm, light cutting action is also the principal attribute of the tough and sharp -L50 geometry, making it suitable for materials such as stainless steel, nickel-based super alloys and titanium. Optimised for use in good operating conditions and heavy application areas, GC1040, GC2040 and S30T are the available grade options.

Alongside -M30 and -L50, size 8, 11 and 14 inserts with a 4mm radius are being made available as standard in -WM geometry, aimed at boosting the milling of automotive parts. Grade options include GC1130, GC1020, GC3040 and GC4330.

Apart from just groove milling, CoroMill 331 is a universal concept that can provide flexible, high-precision machining in numerous face, shoulder, and side and face milling operations across all industry segments. A large assortment covers an extensive choice of diameters, widths, insert geometries, corner radii and grades.

 

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Edd China Discusses Vibration-Damping Technology In New Sandvik Coromant Film

Edd China Discusses Vibration-Damping Technology in New Sandvik Coromant Film

Sandvik Coromant has produced a short film featuring engineer and inventor Edd China Discusses Vibration-Damping Technology in New Sandvik Coromant Film and how they occur, and the principle of tuned mass damping technology.

In the film, Edd China visits Sandvik Coromant in Trondheim, Norway, where world-leading research into vibration-reducing technology for machining is undertaken. During a series of interviews with experts from the company, he learns about how tuned mass damping—a technique that can be applied to control unwanted vibrations—is applied to modern cutting tools.

The film also shows how the concept of tuned mass damping can be dramatically scaled up, with the presenter overseeing the hands-on construction of a simplified model of the Taipei 101 tower to illustrate how tuned mass damping works in practice.

“It doesn’t matter whether the tower is 500m tall, or it’s a tiny tool. They are both subject to the same laws of physics, and both damp vibrations by the same method,” concluded China.

To watch the film, click here.

 

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Sandvik Coromant Upgrades CoroPlus ToolPath For PrimeTurning Software

Sandvik Coromant Upgrades CoroPlus ToolPath For PrimeTurning Software

Cutting tool and tooling system specialist Sandvik Coromant has upgraded the CoroPlus ToolPath for PrimeTurning software to help manufacturers speed up their operations and planning processes. Part of the Sandvik Coromant digitally connected CoroPlus suite of solutions for machine shops, the software facilitates maximum turning productivity and output.

Introduced by Sandvik Coromant through the unique PrimeTurning concept, the all directional turning methodology enabled increased metal removal rates, offered significant time savings and boosted productivity while eliminating many of the misconceptions associated with small entering angles and chip control. The concept proved especially beneficial in mass production industries such as the automotive sector. It was also ideal for short batch production—for example in aerospace and oil and gas—of components in difficult-to-machine materials that require frequent set-up and tool changes.

To get the best out of the process, including more efficient and faster programming, the company launched its CoroPlus ToolPath for PrimeTurning software, which has now been enhanced with a host of new features, functions and an easy-to-use interface. Available in stand-alone and CAM-integrated versions, the software provides the correct grade, geometry selection, and cutting data while ensuring optimal productivity and tool life as well as maximum output. It is also compatible with a wide range of CNC turning machines that use ISO codes, thereby providing automatic storage for component profiles.

The CoroPlus ToolPath for PrimeTurning now supports profiling and facing for external turning in addition to existing programmable support for longitudinal turning. The software also enables CAD models to be imported (in STEP and IGES formats, amongst others) and offers 3D simulation with collision detection.

A key new feature is an improved and intuitive interface for machinists who don’t have CAM software with PrimeTurning support or those doing shopfloor programming, with the option of operating on desktops or mobile devices. The user is able to generate NC code in few quick and easy steps. After the user specifies the operation, machine parameters, workpiece details and material information, the software automatically recommends the right tools to use along with the cutting data. The operator can simply use the suggested solution or alter parameters to get customised results.

Before creating the final NC code, the PrimeTurning tool path software enables the user to run a simulation to verify no collisions and change any parameters as required, then generate a new programme within seconds and run another simulation until the user is satisfied enough to produce the correct code. The software enables the user to stop anywhere they like in the process, running a simulation block by block or going back into the code if preferred.

 

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Sandvik Coromant Extends Advanced Insert Grades To Additional Milling Concepts

Sandvik Coromant Extends Advanced Insert Grades To Additional Milling Concepts

Following the successful introduction of its GC4330 and GC4340 steel milling grades, Sandvik Coromant is now extending the range of application for these advanced insert grades to additional milling concepts. The grades are now available for selection with the CoroMill 300 round-insert face and profile mill; the CoroMill 245 multi-purpose face milling cutter; and the CoroMill QD cutter, which is optimized for deep and narrow grooving and parting off.

GC4330 and GC4340, which feature a specially developed substrate, Inveio coating and enhanced post-treatment technology, allow users to enjoy substantially increased tool life and process security. The extension of these grades to additional Sandvik Coromant milling concepts brings their advantages to even more machine shops looking to optimize the milling of steel workpieces.

Among the many design attributes of GC4330 and GC4340 is the optimized Inveio coating. Inveio is the technical breakthrough of uni-directional crystal orientation in the alumina coating layer that gives inserts a new level of wear resistance and tool life. Furthermore, the substrate of the grades delivers highly controlled grain size distribution for more reliable and predictable insert behaviour.

GC4330 is a medium-hard grade for roughing to semi-finish face milling, while the GC4340 grade is for rough shoulder milling and groove milling. Both grades are also extended to the CoroMill 360 heavy-duty face mill, CoroMill 419 high-feed mill, and LPMH-PM plunge-cutter inserts. In addition, GC4330 is available for the CoroMill 365 high-security face mill, while GC4340 can be applied to the CoroMill 216 ball-nose end mill and CoroMill 415 small-diameter high-feed face mill.

 

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