Bjorn Rosengren, president and CEO of Sandvik, intends to resign and leave the company on February 1, 2020. He will join ABB and succeed Peter Voser as CEO effective March 1, 2020.
The Sandvik Board of Directors are now starting to work to appoint a new president and CEO for Sandvik.
“Since he joined Sandvik in November 2015, Bjorn Rosengren has established a solid decentralised business model for the company and made the organisation more flexible and efficient. The Board is very grateful for his and all the employees’ work during these years. We will initiate the process to assign a very experienced and competent industrial leader that can succeed Bjorn in the role as President and CEO and continue to develop the company even further,” says Johan Molin, Chairman of the Board for Sandvik.
Rosengren is a highly experienced, international executive and leader of industrial businesses. As CEO of Sandvik, he has overseen the successful implementation of a decentralised structure and improved both the profitability and financial strength of the company. Prior to that, he was CEO of Wartsila Corp., which manufactures and services power sources and other equipment for the marine and energy markets (2011-2015), and spent some thirteen years (1998-2011) in a variety of management roles at Atlas Copco, a world leading provider of sustainable productivity solutions.
“This has not been an easy decision. Sandvik is a great company with a lot of future potential and I will continue to lead the organisation with a strong commitment until end of January,” says Rosengren.
Sandvik AB has acquired a 30 percent stake in privately owned Italian company Beam IT, a provider of metal additive manufacturing (AM) services and advanced end-use components.
“The investment in Beam IT will complement our existing offer in additive manufacturing. It is also in line with Sandvik’s strategic ambition to become a leading solution provider for the wider component manufacturing industry,” said Lars Bergström, president of Sandvik Machining Solutions.
Beam IT is a trusted supplier of metal AM end-components to demanding industries, including automotive, energy and aerospace, and holds several relevant quality certifications to serve these industries. The company has more than 20 years of experience within additive manufacturing (AM) and has more than 20 powder bed fusion printers installed.
“The AM sector is developing fast and there is a need for AM-specialist-partners with the advanced skills and resources required to help industrial customers develop and launch their AM programmes. With this investment we provide our customers with the opportunity to access the complementary and combined power of Sandvik and Beam IT,” said Kristian Egeberg, president of the Additive Manufacturing division in Sandvik.
In 2018, Beam IT generated revenues of about SEK70 million, with its 38 employees. Sandvik has the right to further increase its stake over time. The parties have agreed not to disclose the purchase price.
Sandvik has opened a state-of-the-art coiled tubing line for premium grades of seamless stainless-steel products in smaller dimensions at its Zhenjiang tube mill near Shanghai, China. The commitment to produce longer lengths of weld-free coiled tubing locally will enable customers in the Asia Pacific region to receive deliveries within 28 days, instead of waiting four to six months for longer length reels to arrive from abroad.
“The new coiled tube offering is a further step in our commitment to boost the competitiveness of customers in China and throughout the Asia Pacific region,” says Satish Sharath, Business Unit President Sandvik Tube APAC. “We’ve seen a rising demand on projects within chemical processing, oil and gas, alternative energy and other industries for urgent local supplies of coiled tubing. The compact reels, ease of transport and ability to precisely cut lengths in challenging situations allow customers to work fast and efficiently, with fewer connectors and zero risk of system leakage.”
Initially, the focus will be on Sandvik 3R60 (ASTM TP 316/316L) tubing – an austenitic chromium-nickel steel with a minimum of 2.6 percent molybdenum and low carbon content – in outer diameters from 6.0 to 14 mm. The coiled tube is supplied as level-wound on plastic-wrapped wooden reels in standard (55-260 m) or longer lengths (135 – 611 m), or as bulk coil, strapped into boxes. The new range complements Sandvik’s current offering of six-meter straight lengths of hydraulic and instrumentation tubing, which are already available in the widest range of sizes and grades on the market today.
“At first glance, most tubing looks pretty much the same,” says Glenn Darley, Regional Sales and Marketing Director in China. “But numerous tests show that Sandvik truly sets a standard within the various product and grade standards, consistently delivering at the highest levels on key performance criteria such as ovality, corrosion resistance, surface smoothness and tight tolerances. This – and our deep materials expertise – matters a great deal to end users who often discover the hard way that inferior local grades can lead to system leakage, unplanned maintenance or – even worse – a plant shutdown.”
According to Darley, the 28-day delivery promise means, in effect, that Sandvik coiled tubing is now “closer than you think.” In addition to Sandvik 3R60 (ASTM TP 316/316L), the company will supply other grades of high-alloy and duplex tube products in a wide range of dimensions. He encourages customers to ask about these. However, they will be handled on a case-by-case basis, by country, and may be subject to slightly different delivery times than the 28-day guarantee now being offered for standard grades.
“Our aim is to better serve customers in the Asia-Pacific region,” says Paul Tsai, Production Unit General Manager at the Zhenjiang Mill. “The new offering combines advanced production technology and unique manufacturing know-how with extensive technical support.” The mill he oversees, located 250 kilometers northwest of Shanghai, produces straight and U-bent tube for heat exchangers and hydraulic and instrumentation tubing in austenitic and duplex stainless steels as well as high-alloy austenitic stainless steels and nickel alloys.
“Our commitment to China and Asia-Pacific region goes back more than 40 years,” says Satish Sharath. “We have trusted distributors or sales offices in virtually every country, opened our high-tech mill in Zhenjaing in 2011, have another tube mill in India and one in North America, in addition to our main R&D and tube production works in Sandviken, Sweden. In other words, plenty of backup production power.”
The ExOne Company is strengthening its material collaboration with Sandvik Additive Manufacturing to advance binder jet manufacturing. The collaboration leverages ExOne’s knowledge of binder jetting print machines and processes with Sandvik’s expertise in materials technology, metal powders, different additive manufacturing (AM) processes for metals, and post processing technologies like machining and heat treatment.
The material collaboration will focus on qualifying and optimising Sandvik’s Osprey metal powders with ExOne’s binder jetting machines. The collaboration will include studying powder and binder interactions, developing 3D machine process settings, and creating post-processing heat treatments for various materials, initially including stainless steels, tool steels, and nickel alloys. The purpose of the partnership is to create a leading-edge process solution that can be offered to a broad industrial customer base.
“We are excited to announce our material collaboration partnership with Sandvik Additive Manufacturing. Sandvik is a world class engineering company with extensive knowledge of materials and their applications to various industries. We look forward to advancing ExOne’s binder jetting process with this new collaboration and creating new solutions that enable broader customer adoption,” said ExOne CEO John Hartner.
Mikael Schuisky, VP and head of R&D and operations at Sandvik Additive Manufacturing, said, “This material collaboration will strengthen our ongoing R&D cooperation with ExOne even further. It also offers great opportunities to qualify our leading Osprey metal powders for the ExOne platform, to enhance end customer productivity and product performance.”
Sandvik has multiple ExOne binder jetting machines. It is also a beta customer for ExOne’s new X1 25PRO production machine.
Using additive manufacturing (AM), Sandvik Coromant has created CoroMill 390, a lightweight milling cutter that helps minimise vibration and improve security during machining with long overhang.
“When designing our new lightweight CoroMill 390, material has been tactically removed to create the optimal cutter design for minimising mass,” explained Magnus Engdahl, product application manager at Sandvik Coromant. “This is called topological optimisation and it makes the cutter more compact and significantly lighter than a conventional version, thus helping machine shops to boost the productivity of their long-overhang milling operations. Moreover, a shorter distance between the damper in the adaptor and the cutting edge improves performance and process security.”
The CoroMill 390 can perform long-reach face milling, deep shoulder and side milling, cavity milling, and slot milling. The tool is available in 40mm (arbor 16 coupling) and 50mm (arbor 22 coupling) diameter variants. Three or four inserts (size 11) can be specified to suit the application, and differential pitch and internal coolant are provided on all cutters.
Sandvik Additive Manufacturing has created the first-ever 3D printed diamond composite that is perfect for a wide range of industrial uses. Using additive manufacturing (AM), the diamond composites can be formed in almost any shape, opening the possibility of using it in applications that were previously considered impossible.
“We now have the ability to create strong diamond composites in very complex shapes through additive manufacturing, which fundamentally will change the way industries will be able to use this material. As of now, the only limit to how this super-hard material can be shaped and used is down to the designer’s imagination,” said Mikael Schuisky, head of R&D and Operations at Sandvik Additive Manufacturing.
Sandvik’s 3D printed diamond composite has been tested and found to have extremely high hardness, exceptional heat conductivity, while also possessing low density, very good thermal expansion, and fantastic corrosion resistance.
According to Schuisky, the additive manufacturing process used to create the 3D printed diamond composite is highly advanced. “We are printing in a slurry consisting of diamond powder and polymer using a method called stereolithography, where complex parts are produced, layer by layer, using ultraviolet light. The step after the 3D-printing is, however, even more demanding. This is where Sandvik has developed a tailor-made, proprietary post processing method making it possible to achieve the exact properties of the super-hard diamond composite,” he explained.
The diamond composite has been tested and found to have extremely high hardness, exceptional heat conductivity, while also possessing low density, very good thermal expansion and fantastic corrosion resistance. It was unveiled at the RAPID + TCT show, North America’s leading event for additive manufacturing, which is happening this week (May 21–23, 2019) in Detroit, Michigan.
Using digital solutions for monitoring of equipment utilisation makes workshops far more efficient and profitable. Sandvik Coromant has introduced its monitoring system, CoroPlus MachiningInsights which also gathers data, calls attention to issues and provides insights required to take action. It is an easily attainable step for manufacturers that are looking to reduce waste in production and make a smooth transition into a digital way of working.
This digital solution was developed in recognition that a machine that stands idle is not making money. For many manufacturers and workshops, knowing when a machine has stopped – and identifying the underlying reason for the stoppage – can be a major challenge and digital solutions are creating new possibilities to overcome this issue. Replacing the traditional ways of manual tracking, manual data aggregation and manual time studies, collecting data directly from a connected machine tool as well as from operators makes it possible to visualise the machine-, and even tool-, utilisation levels and create improvements within the factory.
Manufacturers are able to make substantial efficiency gains from this digital solution through the ability to analyse equipment utilisation and act to optimise production processes. The analysis itself is facilitated by digital connectivity and by adding the capability of operator input into the system, Sandvik Coromant has ensured there are also opportunities for increased collaboration and greater efficiency by combining data from the operator with data from the machine.
Transparency is ensured through the visualisation being carried out online and, therefore, accessible by a web browser. This means there is a rapid and simple method of incorporating digital manufacturing intelligence into a production site to drive improvements.
With an advanced solution that enables manufacturing companies to take steps towards digital machining and Industry 4.0, Sandvik Coromant has introduced connectivity capability to its series of Silent Tools tool holders. The innovation is offered as part of the company’s CoroPlus suite of connected solutions for machine shops keen to embrace the rapidly advancing trend of industry digitalisation.
Among a number of enhancements, the latest Silent Tools technology for internal turning at long overhangs now feature embedded connectivity within the adaptor. Named Silent Tools Plus, this solution enables data from the machining process to be collected and sent to a dashboard, giving the operator a valuable insight into what is happening inside slender tubular components. For instance, it will be possible to detect if there is too much vibration or if the surface quality is at risk of being compromised. Furthermore, operators will be able to reduce the time that the machine runs without the tool in cut.
“The combination of CoroPlus connectivity and Silent Tools damping technology makes this a solution that shows the technical heights we can expect from the machining solutions of the future,” said Åke Axner, Product Manager Silent Tools Turning Adaptors at Sandvik Coromant. “Silent Tools Plus turning adaptors with embedded connectivity support our overall CoroPlus strategy, which enables customers to work more efficiently.”
By way of example, the Silent Tools Plus vibration indicator is able to detect issues with machining at an early stage, helping to prevent vibration-associated issues such as noise, poor surface quality and accelerated tool wear. Furthermore, centre height setting functionality displays the level of the cutting edge, so that it can be quickly and easily set according to requirements. The result is better machining performance and longer tool life.
The range of Silent Tools from Sandvik Coromant is designed to minimise vibration through a pre-tuned dampener inside the tool body that consists of a heavy mass supported by rubber spring elements. The benefits of this design are multi-faceted, allowing machine shops to increase metal removal rates, improve surface finish, secure the process or reduce production costs.
The Silent Tools Plus turning adaptor also includes a new Wedge Lock quick-change interface between the adaptor and cutting head. The fast and accurate cutting head changes this facilitates will appeal to manufacturers in a variety of industries, including aerospace, for machining components such as landing gear components, and in oil and gas, where the machining of long tubular parts is commonplace.
To strengthen the metal additive manufacturing (AM) industry, Renishaw has initiated a collaboration with Sandvik Additive Manufacturing to supply the company with high productivity multi-laser RenAM 500Q systems, which will substantially increase Sandvik’s printing capacity.
This is one of the largest installations to date of Renishaw’s latest AM system, the RenAM 500Q, which features 500 W quad lasers in the most commonly used platform size, enabling a radical increase in productivity, without compromising quality.
Working with ongoing support from Renishaw, the investment will complement Sandvik’s existing printing technologies and strengthen its position in the growing additive manufacturing market. The two companies also intend to collaborate in areas like materials development, AM process technologies and post-processing.
“Renishaw is a leader and innovator in metal AM and metrology, positioning it as the perfect AM partner,” explained Robin Weston, Marketing Manager of Renishaw’s Additive Manufacturing Products Division. He further added that, “Sandvik is well established throughout the AM value chain, with a leading position in fine metal powder for additive manufacturing and world-leading expertise when it comes to post processing methods like machining, heat treatment and sintering. Our collaboration will strengthen Sandvik’s position during a period of rapid growth in the metal additive manufacturing industries.”
While Kristian Egeberg, President of Sandvik Additive Manufacturing has commented that, “Sandvik has a leading position within the AM metal powder market and has made sizeable investments in different AM printing process technologies for metal components since 2013. The recent addition of multi-laser RenAM 500Q systems will complement our current printing portfolio in a very good way – and our collaboration with Renishaw will benefit both parties when it comes to capitalizing on the expected rapid growth.”
As announced previously, Sandvik has initiated extensive investments, amounting to 200 million SEK, in a new plant for manufacturing of titanium and nickel powders for additive manufacturing. This investment will complement Sandvik’s existing Osprey powder offering, to include virtually all alloy groups of relevance today.
Threads are machined features that exist universally, across all sectors of industry. And despite decades of performing thread-turning operations, advances in the process continue to be made, particularly when it comes to challenging materials such as stainless steel, heat resistant super alloys (HRSAs) and titanium. Contributed by Sandvik Coromant
An example can be seen with the development of thread-turning tools that feature both over- and under-coolant, the combined precision of which serves to extend tool life, elevate thread quality and deliver the potential to run with higher cutting data. The positive effects stand out even more when machining challenging workpiece materials.
Internal and external threading | Image Source: Sandvik
There are many machinability issues with stainless steel (ISO M) and HRSA and titanium (ISO S) materials. With regard to ISO M materials, machinability often decreases with a higher alloy content. And while chip control is fair in ferritic/martensitic materials, it becomes more complex in austenitic and duplex types. Perhaps most troublesome of all is that machining these materials creates high cutting forces in combination with built-up edge and work-hardened surfaces. The combination of these factors serves to compromise tool life.
In terms of ISO S materials, the physical properties and machining behaviour of each varies considerably, due both to the chemical nature of the alloy and the structure of the material. For instance, annealing and aging can be influential on subsequent machining properties. It is well established that chip control is challenging, while the cutting forces and power required to successfully machine ISO S materials are quite high.
Keeping Cool Under Pressure
It’s clear that the use of coolant when machining ISO M and ISO S materials is vital. However, Sandvik Coromant is able to demonstrate that the specific way in which coolant is applied can lead to a multitude of extra benefits in thread-turning operations. The focus here is on precision; utilising jets of coolant from different directions (located close to the cutting edge) to serve specific purposes.
The technology is evident on the newly extended CoroThread 266 range of tools for external thread turning, which offer precision over- and under-coolant to improve process security and maximise efficiency. Over-coolant improves chip formation and removes chips from the cutting area, supporting more secure, trouble-free machining and fewer unplanned stoppages, while under-coolant controls temperature for long and predictable tool life. This configuration of precision coolant also has positive effects on surface finish, further supporting the generation of high-quality threads, while an additional benefit of this innovative technology is that it will allow the tool to run with higher cutting data, therefore reducing cycle times.
Action image from the side | Image Source: Sandvik
Along with precision coolant, process stability is paramount to ensure the turning of threads that are right-first-time. For this reason, CoroThread 266 also features the proprietary iLock interface between the holder and insert, which prevents cutting forces from causing micro-movements of the insert in the tip seat, thus promoting accuracy, surface finish and consistency.
It can even be argued that precision coolant is able to troubleshoot thread-turning issues. For instance, those struggling with chip control and surface quality issues will certainly benefit from the application of over-coolant, which promotes chip evacuation and avoids defects caused by chips. Those with dimensional issues, which are normally attributable to excessive insert temperatures (leading to rapid insert wear), will benefit from the cooling action of under-coolant. In combination – over-coolant and under-coolant—the potential gains are considerable.
During tests measuring average flank wear per part when thread-turning ISO M components, results were compared between standard external coolant and precision over- and under-coolant. Running at 40 bar (580 psi), the amount of flank wear was noticeably less upon comparing the threads turned using external coolant and those produced with precision over-coolant. Flank wear was reduced further still with precision under-coolant. As a general observation, tool life almost doubled.
Through testing it is possible to see that the use of precision coolant can offer significant gains in insert tool life. This effect has also been witnessed during numerous customer trials.
Customer Trial Results
One customer turning Whitworth pipe threads (G 1¼ inch) on SS2333 grade stainless steel parts enjoyed a notable gain in tool life against the best competitor product. Moreover, the use of CoroThread 266, even at less than 10 bar (145 psi) pressure, meant that chip control was greatly improved, with chips no longer sticking to the component and/or tool in the same manner as previously. Chips that stick can cause surface damage to the part, or get jammed between the cutting edge and component, leading to potential insert breakage.
Another customer, this time turning UN threads (60°, 3½ inch, 8 TPI) on AISI 422 stainless steel workpieces enjoyed very impressive increases in both tool life and cutting speeds. Operating with high-pressure coolant, the customer reports being very satisfied with the outcome, which also offered far better chip control. Further tests have demonstrated impressive gains in tool life when performing thread turning on 316L stainless steel parts, as well as Ti6Al4V titanium alloy.
Aside from challenging ISO M and ISO S materials, in many cases the use of precision coolant technology is recommended in steel (ISO P) components, as demonstrated by yet another customer. Despite low pressure of just 7-10 bar (102-145 psi), a machine shop turning 1 inch NPT threads (11½ TPI) on AISI 1215 unalloyed steel witnessed a significant increase in tool life.
In tests on ISO P materials, there are marked reductions in flank wear per component when comparing precision over- and under-coolant at 40 bar (580 PSI) with standard external coolant application. Tests also show that, although the solution demonstrates benefits at less than 10 bar, pressures of 70 bar will provide optimum results in terms of reduced average flank wear
Ultimately, precision coolant effectively removes heat from the cutting edge and provides the possibility to increase cutting speed and thereby achieve higher productivity, with maintained tool life. In addition, precision coolant helps to remove chips from component and tool, and improve chip formation, which in turn boosts process security.