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Achieving Sustainability In Manufacturing

Achieving Sustainability In Manufacturing

The hype of the manufacturing world in recent years is centred on sustainability—of practices, of technology or of waste disposal—for a better future. But what exactly does ‘sustainable manufacturing’ mean, and how can a manufacturer achieve or engage in it? By Michelle Cheong

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Redefining Productivity: New Advances In Inserts Technology

Redefining Productivity: New Advances In Inserts Technology

Customers always look forward to procuring parts and devices from manufacturers that are reliable in providing quality products that achieve output that does minimal to affect the delivery schedule. Staffan Lundström, product management, parting & grooving, and Bimal Mazumdar, product manager, Sandvik Coromant, explain what it takes to achieve such a status.

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Sandvik Coromant: Corobore 826

Sandvik Coromant: Corobore 826

Sandvik Coromant has taken another step in the development of fine boring technology by introducing CoroBore 826, a groundbreaking high-precision (HP) coolant tool for trouble-free machining and close hole tolerances.

Machine stops caused by chip tangling around the tool or spindle are a common problem in fine boring. With the high-precision nozzle, CoroBore 826 HP directs the high-precision coolant jet to the cutting edge in order to efficiently control and break the chip. Chips are then easily evacuated from the hole. Combined with the user-friendly stepwise scale setting of the tool diameter provides the perfect tool for accurate fine boring.

CoroBore 826 HP is the ideal first choice fine boring tool for requirements in the range of 36–1260 mm (1.417–49.606 inch). It is optimised for process repeatability, hence ensuring excellent surface finish and close hole tolerances.

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The Perfect Digital Twin Increases Machining Efficiency

The Perfect Digital Twin Increases Machining Efficiency

Digitalisation of tool selection and assembly creation can increase machining efficiency. By Sandvik Coromant 

While in-machining efficiencies can be seen through advanced tooling technologies and strategies, there are many gains to be had earlier in the process, at the design and planning stage.

Here, the digitalisation of previously manual processes such as tooling item selection and tool assembly creation can help to significantly increase efficiency and machining security.

Cutting tool data can in fact be gathered more accurately and used to create precise digital twin representations—a functionality that has become fundamental in the modern workflow to prevent errors at the machining stage.

Today, such processes can be fully integrated with the user’s CAM software, and can be completed with a few simple clicks as part of an easy-to-use menu-driven process.

Simulating The Tool Assembly

In machining applications, it is not individual tool items such as toolholders, cutters and inserts that are used on machines, but tool assemblies. In many instances this creates a somewhat laborious task for the CAM programmer, where several opportunities for error exist, not least failing to select the optimum tool items in the first instance.

Furthermore, many typical tool assemblies can take up to one hour to create. With some components demanding the use of 25 or more different tool assemblies, this is an enormous overhead to the business in terms of both time and cost.

The challenge isn’t to create the assembly itself—nowadays this can be created in just a few seconds by adding a description and the relevant parameters, for example diameter and length, into a CAM system without any external help.

However, creating a digital twin representation for a tool assembly simulation is far from being a simple task. In order to make the most accurate possible representation of a tool assembly in a CAM system, the creator would first need to search various vendors’ catalogues, download the 3D model files, and assemble them in a CAD programme. Only then can they finally be created as a tool assembly in the CAM system, including the technical parameters.

Streamlined Process

Clearly there is an opportunity to streamline the pre-machining process and make it more agile, something that can be achieved by integrated tool item recommendation and tool assembly creation within the CAM software platform. In this way, it is possible to cut the time required and increase security in design and planning processes.

With regard to tooling item recommendation and selection, an optimised and integrated solution would allow CAM programmers to select from holders, tools and inserts for milling, for example.

Here, users would be able to choose a preferred source, such as a digital catalogue stored locally or a cloud assortment whose data are constantly and automatically updated. Then, once data such as component, type of machining operation and material has been input, users could simply click ‘get results’ to receive the speeds and feeds required for the selected tool.

One such solution is the CoroPlus ToolGuide, which uses an open Application Programming Interface (API) to connect with the CAM software. In short, the software enables users to find a suitable cutting tool for a given task. It creates an organised list of all the suitable tools, with the most economical choice at the top. It will also show the suggested machining process and cutting data.

The list is generated by an algorithm that matches the stated task and conditions with tools. This algorithm holds information about the different machining processes that can be used for different tasks, while the product data on the tool holds information on the machining processes to which the cutter is suited. Importantly, all of the data can be sent to CoroPlus ToolLibrary, where standard tool assemblies can be created ready for export to the CAM or simulation software.

Easy Access To Tool Data

For a productive CAM process, the programmer needs access to tool data which is usually stored in so-called tool libraries. However, most of today’s tool libraries are empty, for a number of reasons, not least because it is difficult to find tool data and keep it up to date. In addition, until recently there has been no industry standard for communicating tool data.

There are approximately 1.2 million manufacturing units in the world today, and all CAM vendors, machine tool builders and tool suppliers have historically had their own way to denominate and structure tool information. This is why ISO 13399 has been created.

Sandvik Coromant, the KTH Royal Institute of Technology and other players in the metal cutting sector are behind the development of ISO 13399, which is now a globally recognised way of describing tool data.

This international standard defines tool attributes such as length, width and radius in a standardised way. Before the standard was written, three different suppliers may have called the diameter D3, D1 or DC2. With ISO 13399, however, the diameter will always be DCX, regardless of supplier.

ISO 13399 also simplifies the exchange of data for cutting tools. When all tools in the industry share the same parameters and definitions, communicating tool information between software systems becomes much easier.

Built on the ISO 13399 structure and open to all tooling suppliers, platforms such as the CoroPlus ToolLibrary ensure there is no longer any need to interpret data from paper catalogues and then manually entering it into the system.

Failsafe System

Additionally, the software allows CAM programmers to work with any tool vendor catalogue compliant to ISO 13399 standards and to create assemblies safe in the knowledge that all suggested items will fit together.

The results can be viewed instantly in 2D and 3D, while users can also digitally store all information about the tools. Once saved, programmers simply import the tool assembly into their CAM or simulation software. All of the tool data is pre-set and a 3D model included.

Streamlined Pre-Machining

Users report that this process makes it possible to cut the time from tool assembly to simulation by at least 50 percent. Plus, there is a much better chance of making the right tool choice in the first instance. Of course, having accurate tool data also means that collisions are possible to detect and avoid during simulation routines due to having the real tool shape and a digital twin representation.

The importance of accessible and accurate tooling data in pre-machining is vital to help address the challenges faced by CAM programmers on a daily basis. Through such latest digital solutions, it is possible to demonstrate how much easier and faster pre-machining tasks can be executed, and ultimately are a step forward in helping manufacturers prepare for Industry 4.0.

ISO 13399:

A Step Towards Data-Driven Manufacturing

With modern manufacturing systems relying more and more on relevant and exact information, ISO 13399 is an international standard that enables cutting tool manufacturers to use the same “language” to describe their products in a computer-interpretable, digital format (such as STEP-File or STEP-XML).

This common format simplifies the exchange of this data between computer systems and software applications.

“With this standard it will be possible to import relevant information directly into a PLM, CAD, CAM, CNC simulation or tool management system,” said Bengt Olsson, project information specialist at product information management at Sandvik Coromant. “It has the potential to both speed up and improve the quality of the planning process of a new job.”

Platforms such as CoroPlus ToolLibrary allow creation of tool assemblies based on standard tool data. The assemblies can be directly imported to CAM or simulation software

Platforms such as CoroPlus ToolLibrary allow creation of tool assemblies based on standard tool data. The assemblies can be directly imported to CAM or simulation software.

 

A more agile and optimised manufacturing is made possible bymaking use of data in the design and planning processes

A more agile and optimised manufacturing is made possible bymaking use of data in the design and planning processes.

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Elements For Successful Face Milling

Elements For Successful Face Milling

Boost productivity in face milling operations with pivotal technologies. Contributed by Sandvik Coromant.

More manufacturers are faced with trying to boost the productivity of face milling operations and reduce component costs in a bid to achieve competitive gain and grow market share.

There are many notable trends in the component milling arena, particularly where batch sizes are above average and where there is a degree of component complexity that makes parts challenging to clamp. When clamping is more unstable, the application becomes prone to vibration.

Here, the typical tools used in larger volume production are double-sided inserts with many cutting edges that are able to positively impact overall productivity and cost per component. Such tools, however, are based on negative concepts that often produce a heavy cutting action, elevated cutting forces and higher energy consumption, along with greater tool wear and burr formation. As a result, in vibration-prone applications, these cutters struggle to meet the high performance levels demanded.

Single-sided insert concepts, although positive, are generally dismissed in higher batch applications due to their limited number of edges.

Positive Effect

It seems clear that a face mill with double-sided, multi-edge inserts that is capable of positiveeffect cutting would prove ideal. This demand is highlighted further as a result of another marked trend in milling strategies that is found particularly in sectors such as automotive – the shift away from fixed transfer lines towards universal, smaller machining centres that can better accommodate mixed production requirements.

While smaller, less powerful machines are a good choice from a production strategy perspective, they are not always suitable for the negative, heavy cutting concepts that these manufacturers traditionally deploy.

As a result of fierce global competition, seemingly eternal cost pressure is another factor that cannot be ignored at modern component machining facilities. However, in higher volume machining, even a small saving per component can equate to large cost reductions in term of overall production. As a result, manufacturing engineers look to optimise their processes on a constant basis, a strategy which includes close scrutiny of cutting tool selection.

Favourably Tilted

To help maximise yield as well as well as to satisfy the need to reduce component costs, new milling cutter innovations are pivotal. With this in mind, Sandvik Coromant has come up with a multi-edge cutter that can produce a positive, light cutting action in a host of different roughing to semi-finishing operations on steel and cast iron workpieces (ISO P and ISO K materials).

The CoroMill 745 offers a total of 14 true cutting edges offering higher depths of cut than comparable existing cutters. It has an unconventional insert inclination angle, which is designed to offer a large, positive angle on the main cutting edge, which in turn enhances chip formation and delivers smooth, soft sound and low cutting forces.

Although a visual inspection of the tool will reveal that the inserts are configured negatively, their combined effect is positive. This helps manufacturers take advantage of situations where productive yet light cutting is required, including where unstable set-ups or lower powered machines are deployed.

In essence, the tool’s positive cutting action mirrors that of a single-sided concept face mill, but instead features cutting edges on both sides of the insert to help lower piece part costs. All face milling operations up to 5.2 mm depth of cut are expected to benefit.

 

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