Tag Archives: Sandvik Coromant

Thinnest parting off and deep grooving tools now available

When material savings are 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.

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The CoroCut OD with ultra thin inserts keeps material waste to a minimum.

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.”

 

www.sandvik.coromant.com

New CoroMill 390 with size 07 inserts introduced

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CoroMill 390 end mill with size 07 inserts

Versatile cutter with unique torque key offers trouble-free milling. Available immediately, Sandvik Coromant offers a new end mill for small diameters. The CoroMill 390 with size 07 inserts is a versatile cutter that is ideal for shoulder milling, deep shoulder milling, edging, linear and helical ramping, plunge milling, slot milling and face milling. From roughing to finishing, it offers reliability, precision and productivity.

Suitable for all machine types, the CoroMill 390 with size 07 inserts is ideal for mixed production and can be used with different materials and applications. General engineering shops, as well as specialized business segments, such as automotive and oil and gas component manufacturers, will benefit from its universal capabilities.

Grades for the CoroMill 390 with size 07 inserts are available for all of materials. The new insert grade GC1130, produced with Zertivo technology, gives this cutter an extra dimension of security when milling steel. The smaller inserts deliver higher cutter-teeth density for superior productivity.

A unique feature of this tool is the torque key that is specifically designed for size 07 inserts. This key provides consistent clamping every time. It has built-in spring functionality that allows you to mount inserts with the correct clamping force for reliable and consistent tool life. Coolant-through technology is standard on the CoroMill 390 with size 07 inserts for additional heat and chip control.

Troy Stashi, milling product specialist for Sandvik Coromant, says, “The CoroMill 390 with size 07 inserts is the most versatile small diameter end mill on the market today. It’s beneficial for anyone who machines small features in any size component including medical, automotive, and oil and gas parts.”

www.sandvik.coromant.com/en-gb/campaigns/pages/made-for-milling.aspx

Sandvik Coromant extends indexable insert drill capabilities to deliver improved hole quality and longer tool life

Sandvik Coromant has launched a reinforced variant of its CoroDrill® 880 indexable drill that will substantially improve production economy in large diameter hole-making applications. The latest CoroDrill 880 tool body is compatible with a range of insert grades, including a grade based on the company’s new Zertivo™ technology, which delivers optimized cutting edge integrity.

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Representing the latest breakthrough in U-drill evolution, the reinforced CoroDrill 880 features a new enhanced drill body that is up to 30% stiffer than its predecessor for applications of four to five times the drill diameter. This gives a more reliable drilling experience and a much better hole quality. In addition, the combination of enhanced drill body and the new Sandvik Coromant grade chain for steel and cast iron results in a considerable improved insert tool life.

In tests, a customer manufacturing slewing rings for the wind power industry tried the new and improved tool body for CoroDrill 880 in application requiring holes of five times the drill diameter. When using the old tool body in 42CrMo4, the hole size decreased over time providing an undersized hole after a period of use. With the new, stronger tool body, CoroDrill 880 produced correctly sized holes for a much longer period of use. In addition, the customer saw a tool life increase of 975%.

Two of the insert grades, GC4324 and GC4334, are designed with Inveio™ coating for better wear resistance. The third, GC4344, produced with Zertivo™ technology, provides great edge-line security as a result of optimal coating and substrate adhesion properties.

These three grades complete the full grade chain with solutions for all ISO P and ISO K materials and a large variety of applications:

• GC4324: Productivity booster for stable conditions
• GC4334: First choice for good to average conditions
• GC4344: Excellent performance in difficult conditions

The new grade positioning is designed to make it easier to select the right grade from the start.

The CoroDrill 880 product range covers hole diameters from 12 to 84 mm (0.472-3.307 inch) off the shelf, as well as engineered solutions up to 129 mm (5.078 inch). The drills produce holes with tolerances of H12–13 and are suitable for holes up to five times the drill diameter.

www.sandvik.coromant.com/en-gb/products/news/Pages/default.aspx#new-drilling-tools.

Lower costs per steel component: new GC4305 from Sandvik Coromant for shorter cycle times in the automotive industry

In the automotive industry, steel continues to be the most important material by far. To further optimize steel machining processes in this industry, Sandvik Coromant has developed GC4305, an insert that offers both extremely high metal removal rates and stable conditions. With its outstanding performance at high cutting data and its dry machining capability, it offers companies the benefit of reduced cycle times and lower costs per component.

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Cutting tool and tooling systems specialist Sandvik Coromant introduces the new GC4305, an insert for steel turning that maximizes metal removal rates, shortens processing times and enables superior component quality. The outstanding performance it delivers at high temperatures and high cutting data makes GC4305 especially efficient at cutting steel components. With the company’s wear-resistant Inveio™ coating, this new grade of insert achieves the long tool life that is so crucial in the highly competitive automotive industry.

The innovative, heat-resistant cutting material is also suitable for dry machining, making it the ideal solution for automotive component manufacturers seeking to avoid the stresses to which tools are subjected from unwanted temperature fluctuations. This, too, results in a longer tool life. In combination with the high processing speeds typical of dry machining, costs per component can be substantially reduced. Costs are further lowered by decreasing costs for cooling lubricant, recycling and disposal, thanks to, among other things, the elimination of cooling lubricants and associated wastes, lower capital investment, and cheaper disposal of chips.

www.sandvik.coromant.com/en-gb/industrysolutions/automotive

Gear Summit 2015 captures the macro view and future vision for the industry

Sandvik Coromant successfully hosted the first-ever Gear Summit on March 16th to 19th 2015 in Sandviken, Sweden. Twenty-five of the world-leading decision-makers and experts from the gear industry were invited to discuss the common challenges and the future of gear manufacturing.

Attendees of the first ever Gear Summit on March 16th to 19th 2015 in Sandviken, Sweden
Attendees of the first ever Gear Summit on March 16th to 19th 2015 in Sandviken, Sweden

Axel Küpper, Manager Marketing and Business Development, Gear Milling Solutions, at Sandvik Coromant stated the goal of the summit by saying, “In a world characterized by its increasing tempo, it is more important than ever that we gather to create a common platform and make sure we are working towards the same goal.”
The manufacturing industry has an interesting journey ahead, that’s for sure. “The goal with Gear Summit 2015 is not just to keep updated with the latest game-changers, but to stay one step ahead,” Axel Küpper elaborated.

The discussion and workshop touched upon the opportunities and threats for the gear industry from four different perspectives: political, economic, social and technological. Some of the commonly agreed priorities were:

• The importance of raising awareness about the vital role gear manufacturing plays in the global economy, especially when it comes to policy and decision-makers
• New cutting technologies are about to transform the gear manufacturing business. How manufacturers respond to this shift in technology will shape the future of the competitive landscape
• A rapidly growing middle class will increase demand for products, making the shortage of resources such as raw materials, energy and know-how one of the greatest challenges for future generations
• Gear manufacturing presents advantageous future career opportunities to our future generation, especially within R & D. The challenge is in retaining and attracting the right competences

“It is a great opportunity to gather the top leaders under the same roof and discuss how we, as a group, can come up with solutions to improve our industry. If we manage to do that, it will enhance our ability to improve the situation out in the market place,” said David Goodfellow, CEO at Star SU, one of the world’s largest gear machine and gear tool manufacturing producers.
There were also lively discussions about how to meet challenges in new markets such as Africa and China.“If we can identify at least one or two actions that will help us to bring the best out of the new opportunities into industrial application, that I think would be beneficial,” said Jannik Henser, representing the application-oriented research organization Fraunhofer.

Besides a number of insightful presentations from top leaders from manufacturers like Scania and Siemens, the meeting also gave the opportunity to network, thus encouraging different perspectives from the gear manufacturing industry.

The main part of the event took place in Sandviken in Sandvik Coromant’s new center for metal cutting technology. The event also included a guided tour at Sandvik Coromant’s production plant in Gimo and a visit to Sandvik’s headquarters in Stockholm.

Participant List:

American Gear Manufacturers Association, Siemens, Scania, RWTH Aachen and Fachhochschule Aalen, Fraunhofer, Klingelnberg, Liebherr, Gleason, Star SU and DMG, JTekt, Assiot, Ovako and Overton Chicago Gear.

SpiroGrooving – revolutionizing solution for seal ring groove machining

SpiroGrooving – an innovative method for seal ring grooves developed by Sandvik Coromant ensures high output of quality components and meets tough security demands. Used with the CoroBore XL system, it utilizes a spirograph tool path to create close-tolerance seal ring grooves in a very secure and productive way

SpiroGrooving™ - an innovative method for seal ring grooves
SpiroGrooving™ – an innovative method for seal ring grooves

Machining challenges
Requiring close tolerances and high-quality surface finish, seal ring grooves is a critical feature on many oil and gas components. Conventional methods for machining seal ring grooves often suffer from slow production and poor process security. Multiple-operation approach incorporating both roughing and finishing sequences is another time thief. The tools that are being used are single point- or plunging cutters that are prone to vibration. Adding to the challenges is the common use of difficult-to-machine materials such as solid Inconel 718 and cladded Inconel 625. SpiroGrooving is a machining method used with the CoroBore XL system that utilizes a spirograph tool path to create close-tolerance seal ring grooves in a very secure and productive way.

High quality and process security
This solution is ideal for making seal ring grooves in pre-clad machining of steel and stainless steel. The unique internal coolant feature of CoroBore XL facilitates machining in advanced materials. Roughing and finishing are carried out in the same operation, which significantly reduces machining time and improves productivity. Altogether, this ensures high output of quality components and process security when machining seal ring grooves.

How it works
SpiroGrooving uses a circular spirograph tool movement in a taper. This reduces chip thickness, enabling light cutting action and increased feed. Parts of the insert cutting edge have an interrupted cutting behaviour, eliminating long chips tangling to the tool and spindle. With a unique NC-code generator, SpiroGrooving is programmed just in a few easy steps.

www.sandvik.coromant.com/en-gb/knowledge/calculators_and_software/spirogrooving/pages/default.aspx.

Sandvik Coromant support for automotive sector embraces extensive machining solutions for transmission shafts

Range of tools and high-performance grades address challenges to deliver improved productivity, security and tool life in transmission shaft machining

Transmission shaft machining solutions include soft stage turning with GC4325 and GC4315 high-performance turning grades
Transmission shaft machining solutions include soft stage turning with GC4325 and GC4315 high-performance turning grades

The Sandvik Coromant portfolio of automotive component manufacturing solutions offers a selection of tools and insert grades designed to optimize the machining of transmission shafts.

Beginning with soft stage steel turning, high-performance GC4325 and GC4315 insert grades for internal and external operations offer superior levels of wear resistance, the ability to withstand high cutting temperatures and cutting edges that stay in shape for long times in cut.

Moving to hard part turning, CBN inserts are the first choice for turning high quality steel surfaces in the hardness range 58-65 HRc. CBN inserts from Sandvik Coromant have wiper options optimized for specific applications: WH (wiper HPT) generates low cutting forces for best surface integrity, while WG (wiper general) permits higher feed capacity.

The CoroCut® 1-2 grooving programme offers a number of benefits to those machining transmission shafts. For instance, patented spring clamping delivers high rigidity and clamping force accuracy, while both over- and under high precision coolant is available and easily connected via plug and play adaptors. What’s more, CoroCut 1-2 is now available in GC4325 high performance grade for steel.

Clearly, as a transmission shaft, these complex components demand numerous gear and spline milling operations. Among the tools ideal for addressing this challenge is CoroMill 176, an innovative indexable insert cutter for productive gear wheel machining that is designed for gears in the module range 4 to 10. Also, deployed widely for transmission shaft applications are the CoroMill 172 disc cutter for milling high-quality gear profiles and, similarly, CoroMill 171 for small gear modules. The latter features inserts with two cutting edges, while the same cutter body can hold inserts for different gear profiles.

Other gear and spline profiles on transmission shafts can be tackled using InvoMilling™, the unique Sandvik Coromant approach to milling spur and helical gears using indexable insert cutters, along with CoroMill 161 and 162. Using this single tool set on multi-task machines or five-axis machining centres it is possible to create many different profiles by simply changing the CNC program instead of changing the tool.

www.sandvik.coromant.com/en-gb/industrysolutions/automotive/transmission/pages/shafts.aspx.