Sandvik Coromant shapes the future of manufacturing

Held March 29-30 at the Sandvik Coromant Center in Sandviken, Sweden. The company’s heritage is steel, but the real history of Sandvik Coromant begins in 1942 when Wilhelm Haglund was assigned the job as manager for a new production unit for cemented carbide tools in Sandviken. And 75-years later its tools are used all over the world in the manufacturing of as diverse products as aeroplanes and more.

With extensive investments in research and development Sandvik Coromant create unique innovations and set new productivity standards together with their customers. During the two days, the company presented a few new recent developments in tooling and technology for the future.

Helping manufacturing plants access Industry 4.0

Cutting tool and tooling systems specialist Sandvik Coromant presents its CoroPlus® suite of IIoT solutions as part of the company’s contribution to manufacturing in Industry 4.0. The CoroPlus concept is designed specifically to improve the control of productivity and costs through a combination of connected machining and access to manufacturing data and expert knowledge.

The CoroPlus suite consists of tools and software that can send and/or receive data. Using connected technology and machining knowledge from Sandvik Coromant, the suite makes it possible to reduce data waste and improve manufacturing processes in design and planning and in-machining.

With CoroPlus, users not only get access to Sandvik Coromant product and application data through connected software, but with sensor-equipped tools they can adjust, control and monitor machining performance in real time. The CoroPlus concept demonstrates how the machine shop’s productivity can be increased via accurate on-site data dashboards, through the cloud and via integration with the user’s software and machine environment. CoroPlus connects into existing software environments through open Application Programming Interfaces (APIs), offering two-way connectivity and accurate data.

The main benefit the CoroPlus concept offers is the ability to optimise manufacturing through better understanding and insight into what’s happening in the workshop and machining environment. Access to accurate tool and application data inside the existing workflow enables considerable time savings to be made. Also, specific sensor-equipped solutions can be controlled to ensure breakages are avoided and performance is secured, with data intelligence collected live throughout the machining process.

The new Sandvik Coromant suite consists of the CoroPlus ToolGuide which connects directly to a user’s CAM or tool management software, the CoroPlus ToolLibrary which enables the user to create virtual tool assemblies from any supplier’s ISO 13399 standard tool catalogue, the CoroBore® + remote tool set-up system, the in-cut monitoring solution Silent Tools™ +, the Promos 3+ data collector which monitors tools and processes in real time, and the PrimeTurning™ code generator which creates ISO programming codes that are compatible with various CNC systems.

A revolution in turning

Sandvik's PrimeTurning™ methodology and supporting tools provide manufacturers, particularly in aerospace and automotive sectors, with the industry’s first true ‘all directional turning’ solution.

Unlike conventional turning operations – which have remained largely unchanged for decades – PrimeTurning allows machine shops to complete longitudinal (forward and back), facing and profiling operations with a single tool. The methodology is based on the tool entering the component at the chuck and removing material as it travels towards the end of the component. This allows for the application of a small entering angle, higher lead angle and the possibility of machining with higher cutting parameters. Furthermore, conventional turning (from part-end to chuck) can be performed using the same tools.

Sandvik Coromant believes that some applications could see productivity increases in excess of 50% through the deployment of PrimeTurning rather than conventional techniques. Some of these improvements are due to the small entering angle and higher lead angle, which creates thinner, wider chips that spread the load and heat away from the nose radius. The result is both increased cutting data and extended tool life. In addition, as cutting is performed in the direction moving away from the shoulder, there is no danger of chip jamming (a common and unwanted effect of conventional longitudinal turning). Higher machine utilization due to reduced set-up time and fewer production stops for tool changes also enhances overall productivity.

PrimeTurning will be particularly beneficial to manufacturing industries such as aerospace and automotive where there is a need to perform external turning operations in big batch productions or where multiple set-ups and tool changes are often required.

“Experienced operators know that a small entering angle allows for increased feed rates,” says Håkan Ericksson, Global Product Specialist at Sandvik Coromant. “However, in conventional turning they are restricted to using entering angles of around 90° to reach the shoulder and avoid the long, curved chips that a small entering angle characteristically delivers. PrimeTurning solves these problems by combining a perfect reach at the shoulder and the application of 25-30° entering angles with excellent chip control and maintained tolerances. This innovation presents countless possibilities to perform turning operations in much more efficient and productive ways. It’s not just a new tool, but a totally new way of turning.”

PrimeTurning is initially supported by the introduction of two dedicated CoroTurn® Prime turning tools and the PrimeTurning code generator, which supplies optimised programming codes and techniques. CoroTurn Prime inserts have three edges/corners; one for longitudinal turning, one for facing and one for profiling, thus delivering efficient edge utilisation and longer tool life.

Two unique and dedicated inserts are offered: CoroTurn Prime A-type features three 35° corners and is designed for light roughing, finishing and profiling, while CoroTurn Prime B-type with its ultra-strong corners is designed specifically for rough machining. Suitable for ISO P (steel), S (heat-resistant super alloys and titanium) and M (stainless steel) category materials, nine CoroTurn Prime A-type and six CoroTurn Prime B-type inserts are currently available, with expansion to other materials envisioned for the future. The inserts are supported by 52 variants of tool holder, including Coromant Capto^®, CoroTurn QS and shanks.

The PrimeTurning code generator not only ensures maximum output but also process security with suitably adjusted feed rate and entry radius parameters. It creates ISO codes that are compatible with various CNC systems.

These new tooling developments demonstrate how the company is leveraging its machining and manufacturing experience and knowledge toward developing new advances in the future. Sandvik continues to introduce an average of six new tool designs each day. Many of these developments also serve as an example of how the increasing integration of new software technology, as shown with those used for the Prime Turning and CoroPlus platforms, will continue to impact how shops approach machining in the coming years.